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Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s more than only a advertising promise! Over 50 drawings of assorted elements served as the idea for the automation resolution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s components did have one factor in frequent, they had been all rotationally symmetrical. This was the beginning point for welding machine manufacturer EWM in their mission to develop a customized automation solution tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used all round the world for transporting liquids utilizing centrifugal pumps. Their areas of application embrace refineries, energy crops and nuclear vegetation, in the transport of liquefied pure fuel (LNG), as properly as in offshore rigs. They are also used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The goal is to weld all pump safety valve parts 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 circulate conditions. The pump safety valve is largely made up of the valve physique and the cone, which moves inside the valve physique. The sealing surfaces between the valve body and the cone should be completely air and watertight. This is the one means to ensure proper functioning of the pump safety valve for decades to come. Normally, these elements are made using low-cost construction steel DIN 1.0460. The sealing surfaces are strengthened with chrome steel DIN 1.4370. This course of was previously carried out manually, nonetheless, due to each the scarcity of fine welders and growing quality assurance necessities, automation of this step was crucial. The inside diameter of the valve bodies and the cone diameters have been between 32 mm and 400 mm. The elements being moved additionally differed vastly in weight, ranging from a few hundred grams to 2 and a half tonnes. But all the parts had one thing in frequent: they were all rotationally symmetrical, making them good for an automated course of. With this as a beginning point, EWM was in a place to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly grew to become clear that solely a robotic system would match the invoice when it got here to automating this particular process. Having to deal with so many alternative half sizes was a trigger for concern. Large elements require a big welding positioner. These, however, can not present the dynamics required for the smaller components. This shortly gave rise to the idea of three processing stations: one large L-positioner with tilting operate for the big valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench without positioners for any other elements. The height of the constructing was additionally a particular problem. The elements had to have the flexibility to be positioned on the benches with the crane. The crane hook, however, was solely approximately three metres high – extremely small for an industrial software. To assure accessibility whereas ensuring extraction, either the extraction hood or the system benches were made to be cellular. The robotic was fitted in an especially small sales space in the centre between the three stations. This sales space also consists of each the facility 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 one hundred iD in all three stations at all necessary positions is also ensured due to the intense arm length of two metres and optimised space inside the booths.
Special torch for extreme spaces
Each valve physique is provided with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extremely troublesome. For handbook welding, the welder is unable to see the weld seam and as an alternative must rely on their experience. Even for automated เกจวัดแรงดันถังลม , these spaces are very unusual. EWM was only capable of settle for this job because 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 particularly small torch head and unconventionally lengthy torch neck. Of course, the special software needed to be tailored to accommodate this unusual design: as a end result of dilution between the father or mother metallic and the armouring needs to be as little as potential, solely somewhat power is used. This ensures secure warmth dissipation despite the acute welding torch dimensions.
Secure welding outcomes via outlined parameters
As the components have been rotationally symmetrical, it was easy to show the parts; teaching is always primarily based on the same programs. Even new parts may be welded mechanically shortly. Users simply should set the radius, number of passes and the geometric dimensions of the surfaced parts and the robot management will take care of the remaining. The desired welding result’s all the time guaranteed as a outcome of the welding process is defined with all of its parameters. The quality may additionally be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was initially designed and meant for one particular software, Schroeder is already thinking of recent ideas and makes use of. Schroeder would like to try out a few of the varied welding procedures which are included within the Titan XQ welding machine as commonplace. This will allow to further optimise different sorts of surfaced elements. Schroeder are also looking to expand and enhance the range of welding tasks.
There are lots of of Schroeder Valves installed in crops in southern Africa defending assets at firms like Sasol, Eskom, Mondi and Sappi to name a couple of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning services can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please pressure gauge ดิจิตอล @valve.co.za, www.valve.co.za or telephone 011 397 2833 or 0861 103 103 to be taught extra.
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