Automated surfacing of rotationally symmetrical parts
Everything from a single supply – it‘s greater than only a advertising promise! Over 50 drawings of varied parts served as the premise for the automation resolution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one factor in common, 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 resolution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of utility include refineries, power crops and nuclear plants, within the transport of liquefied pure fuel (LNG), in addition to 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 aim is to weld all pump safety valve parts mechanically. These valves are connected directly to the pumps and guarantee continuous operation of the pumps to prevent them running dry or being damaged by cavitation throughout minimal flow circumstances. The pump protection valve is essentially made up of the valve body and the cone, which moves inside the valve body. The sealing surfaces between the valve body and the cone have to be completely air and watertight. This is the one means to make sure correct functioning of the pump protection valve for decades to return. Normally, these parts are made utilizing low-cost development steel DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This process was beforehand performed manually, however, as a outcome of each the shortage of good welders and rising high quality assurance necessities, automation of this step was crucial. The internal diameter of the valve our bodies and the cone diameters had been between 32 mm and four hundred mm. The elements being moved additionally differed vastly in weight, ranging from a quantity of hundred grams to 2 and a half tonnes. But all of the elements had one factor in frequent: they had been all rotationally symmetrical, making them perfect for an automatic course of. With this as a starting point, EWM was in a place to get the system planning ball rolling.
From ส่วนประกอบpressuregauge to Big – Multiple Processing Stations
It quickly became clear that solely a robotic system would fit the bill when it came to automating this specific process. Having to deal with so many various half sizes was a trigger for concern. Large components require a big welding positioner. These, however, can’t present the dynamics required for the smaller parts. This shortly gave rise to the thought of three processing stations: one giant L-positioner with tilting perform 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 another components. The peak of the building was also a selected challenge. The elements had to have the flexibility to be positioned on the benches with the crane. The crane hook, nevertheless, was solely roughly three metres high – extremely small for an industrial software. To assure accessibility while ensuring extraction, either the extraction hood or the system benches were made to be cell. The robot was fitted in a particularly small sales space in the centre between the three stations. This booth also consists of each the ability 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 robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate one hundred iD in all three stations in any respect necessary positions can additionally be ensured because of the intense arm size of two metres and optimised area inside the booths.
Special torch for extreme areas
Each valve body is provided with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extremely troublesome. For manual welding, the welder is unable to see the weld seam and as a substitute should depend on their expertise. Even for automated welding, these areas are very unusual. เกจวัดแรงดันดิจิตอล was solely in a place to accept this job as a result of they manufacture the torches, emphasising the importance of the welding torch for this application. The welding torch for Schroeder Valves is a special construction with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special software needed to be tailored to accommodate this uncommon design: as a end result of dilution between the parent metallic and the armouring needs to be as low as potential, only a little power is used. This ensures secure warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding results through defined parameters
As the elements were rotationally symmetrical, it was simple to show the elements; teaching is all the time based on the same programs. Even new components can be welded automatically shortly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot management will deal with the remaining. The desired welding result is at all times assured as a result of the welding process is defined with all of its parameters. The high quality can be confirmed retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was originally designed and meant for one particular utility, Schroeder is already thinking of latest concepts and uses. Schroeder wish to check out a variety of the varied welding procedures which are included in the Titan XQ welding machine as standard. This will enable to additional optimise totally different sorts of surfaced elements. Schroeder are additionally trying to broaden and enhance the range of welding tasks.
There are tons of of Schroeder Valves installed in crops in southern Africa protecting assets at corporations like Sasol, Eskom, Mondi and Sappi to call a quantity 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 be taught more.
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