Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s greater than just a advertising promise! Over 50 drawings of varied parts served as the premise for the automation answer developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one thing in common, they have been all rotationally symmetrical. This was the place to begin for welding machine producer EWM in their mission to develop a customized automation resolution tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all round the world for transporting liquids utilizing centrifugal pumps. Their areas of application embrace refineries, energy plants and nuclear plants, within the transport of liquefied pure gasoline (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The purpose is to weld all pump protection valve components routinely. These valves are linked directly to the pumps and guarantee continuous operation of the pumps to prevent them running dry or being broken by cavitation throughout minimum flow conditions. The pump safety valve is essentially made up of the valve body and the cone, which strikes inside the valve physique. The sealing surfaces between the valve body and the cone should be completely air and watertight. This is the only means to ensure proper functioning of the pump safety valve for decades to return. Normally, these elements are made using low-cost construction metal DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This course of was beforehand carried out manually, nonetheless, because of each the shortage of good welders and growing high quality assurance requirements, automation of this step was essential. The inner diameter of the valve bodies and the cone diameters have been between 32 mm and 400 mm. The parts being moved also differed vastly in weight, ranging from a few hundred grams to 2 and a half tonnes. But all of the parts had one factor in widespread: they had been all rotationally symmetrical, making them perfect for an automatic process. With this as a starting point, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon turned clear that only a robot system would match the invoice when it got here to automating this explicit course of. Having to cope with so many alternative part sizes was a trigger for concern. Large elements require a big welding positioner. These, however, can’t provide the dynamics required for the smaller elements. This rapidly gave rise to the concept of three processing stations: one massive L-positioner with tilting function for the massive valve bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a third station with a system bench with out positioners for another elements. The peak of the building was additionally a specific challenge. The parts had to have the flexibility to be placed on the benches with the crane. The crane hook, however, was solely approximately three metres high – extremely small for an industrial application. To assure accessibility while guaranteeing extraction, either the extraction hood or the system benches were made to be cellular. The robotic was fitted in an extremely small sales space in the centre between the three stations. This booth additionally consists of each the power source and a Titan XQ. These are positioned behind the L-positioner on the large processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect necessary positions can be ensured because of the acute arm size of two metres and optimised house inside the cubicles.
Special torch for excessive areas
Each valve body is provided with a cone guide which is welded from above. With an inside diameter of just 32 mm, entry is extremely difficult. For handbook welding, the welder is unable to see the weld seam and as an alternative must depend on their expertise. Even for automated welding, these spaces are very uncommon. EWM was solely capable of accept this job as a outcome of they manufacture the torches, emphasising the significance of the welding torch for this software. The welding torch for Schroeder Valves is a particular construction with a very small torch head and unconventionally lengthy torch neck. Of course, the special software had to be adapted to accommodate this uncommon design: as a end result of dilution between the mother or father metallic and the armouring must be as little as attainable, only a little energy is used. This ensures protected warmth dissipation regardless of the intense welding torch dimensions.
Secure welding results via defined parameters
As the components had been rotationally symmetrical, it was straightforward to show the parts; teaching is at all times based on the identical programs. Even new components can be welded mechanically shortly. Users merely should set the radius, number of passes and the geometric dimensions of the surfaced elements and the robotic control will deal with the rest. The desired welding result is always guaranteed as a result of the welding process is defined with all of its parameters. The quality can also be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was initially designed and intended for one particular software, Schroeder is already thinking of new concepts and uses. Schroeder wish to try out some of the various welding procedures which are included in the Titan XQ welding machine as commonplace. This will permit to additional optimise totally different sorts of surfaced elements. Schroeder are additionally trying to expand and enhance the range of welding duties.
There are lots of of Schroeder Valves put in in vegetation in southern Africa protecting property at firms like Sasol, Eskom, Mondi and Sappi to name a couple of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. เกจ์วัดแรงดัน and reconditioning amenities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact [email protected], www.valve.co.za or phone 011 397 2833 or 0861 103 103 to be taught extra.
Automated surfacing of rotationally symmetrical parts