Automated surfacing of rotationally symmetrical elements

Everything from a single source – it‘s greater than just a advertising promise! Over 50 drawings of varied parts served as the idea for the automation solution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one factor in widespread, they have been all rotationally symmetrical. This was the place to begin for welding machine manufacturer EWM in their mission to develop a customized automation solution tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all around the world for transporting liquids using centrifugal pumps. Their areas of application include refineries, energy plants and nuclear plants, in the transport of liquefied natural gas (LNG), as properly as in offshore rigs. They are additionally used throughout the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The purpose is to weld all pump safety valve components routinely. These valves are related on to the pumps and ensure continuous operation of the pumps to stop them running dry or being broken by cavitation throughout minimum flow conditions. The pump protection valve is essentially made up of the valve body and the cone, which strikes inside the valve body. The sealing surfaces between the valve body and the cone must be absolutely air and watertight. This is the one method to make sure proper functioning of the pump protection valve for decades to return. Normally, these elements are made using low-cost development metal DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This process was beforehand performed manually, however, due to both the scarcity of excellent welders and growing high quality assurance necessities, automation of this step was crucial. The inside diameter of the valve our bodies and the cone diameters have been between 32 mm and 400 mm. The parts being moved additionally differed vastly in weight, ranging from a few hundred grams to 2 and a half tonnes. But all the elements had one thing in common: they were all rotationally symmetrical, making them perfect for an automated process. With this as a place to begin, EWM was capable of get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It quickly became clear that only a robot system would fit the invoice when it got here to automating this specific course of. Having to take care of so many different part sizes was a trigger for concern. Large elements require a big welding positioner. เกจวัดแรงดันไอน้ำ , nevertheless, can not present the dynamics required for the smaller parts. This quickly gave rise to the thought of three processing stations: one large L-positioner with tilting operate for the massive valve bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench with out positioners for any other elements. The height of the building was also a particular problem. The elements had to have the ability to be positioned on the benches with the crane. The crane hook, however, was solely approximately three metres high – extraordinarily small for an industrial utility. To assure accessibility while guaranteeing extraction, either the extraction hood or the system benches have been made to be mobile. The robotic was fitted in an especially small booth within the centre between the three stations. This sales space also contains each the facility source and a Titan XQ. These are positioned behind the L-positioner at the massive processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations at all essential positions can additionally 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 supplied with a cone guide which is welded from above. With an inside diameter of simply 32 mm, entry is extraordinarily troublesome. For manual 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 unusual. EWM was solely capable of settle for this job because they manufacture the torches, emphasising the significance of the welding torch for this utility. 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 application needed to be adapted to accommodate this uncommon design: as a end result of dilution between the mother or father steel and the armouring needs to be as low as potential, solely slightly power is used. This ensures safe warmth dissipation despite the extreme welding torch dimensions.
Secure welding results via defined parameters

As the parts had been rotationally symmetrical, it was straightforward to show the components; educating is all the time based mostly on the same applications. Even new parts may be welded automatically shortly. Users merely have to set the radius, variety of passes and the geometric dimensions of the surfaced components and the robot management will take care of the remaining. The desired welding result is at all times assured because the welding process is defined with all of its parameters. The high quality can be confirmed retrospectively as all welding parameters are repeatedly monitored and recorded. Even though the system was originally designed and intended for one specific software, Schroeder is already considering of recent concepts and makes use of. Schroeder wish to try out a few of the various welding procedures which may be included within the Titan XQ welding machine as normal. This will allow to further optimise different sorts of surfaced parts. Schroeder are additionally looking to increase and enhance the vary of welding duties.
There are hundreds of Schroeder Valves installed in plants in southern Africa protecting property at firms like Sasol, Eskom, Mondi and Sappi to call a couple of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning amenities can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or cellphone 011 397 2833 or 0861 103 103 to learn extra.
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