Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s greater than only a marketing promise! Over เกจวัดแรงดันลมคือ of varied parts served as the premise for the automation answer developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one thing in frequent, they had been all rotationally symmetrical. This was the starting point for welding machine producer EWM in their mission to develop a custom automation solution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of utility embody refineries, energy vegetation and nuclear plants, in the transport of liquefied natural fuel (LNG), in addition to in offshore rigs. They are additionally used all through 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 protection valve components mechanically. These valves are connected directly to the pumps and ensure continuous operation of the pumps to forestall them running dry or being broken by cavitation throughout minimal circulate circumstances. The pump protection valve is basically made up of the valve body and the cone, which moves contained in the valve body. The sealing surfaces between the valve body and the cone have to be absolutely air and watertight. This is the only method to ensure correct functioning of the pump protection valve for decades to come. Normally, these components are made using low-cost building metal DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This course of was beforehand performed manually, nonetheless, because of both the scarcity of fine welders and rising high quality assurance requirements, automation of this step was crucial. The inner diameter of the valve our 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 two and a half tonnes. But the entire 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 able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It soon turned clear that solely a robot system would fit the invoice when it came to automating this specific course of. Having to cope with so many alternative part sizes was a cause for concern. Large components require a big welding positioner. These, nonetheless, can’t provide the dynamics required for the smaller elements. This shortly gave rise to the concept of three processing stations: one massive L-positioner with tilting operate for the large valve our bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a 3rd station with a system bench with out positioners for some other parts. The peak of the constructing was additionally a selected problem. The elements had to find a way to be positioned on the benches with the crane. The crane hook, however, was only approximately three metres high – extremely small for an industrial software. To guarantee accessibility while making certain extraction, both the extraction hood or the system benches have been made to be mobile. The robotic was fitted in a particularly small sales space within the centre between the three stations. This booth additionally consists of both the facility source and a Titan XQ. These are positioned behind the L-positioner on the giant 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 can also be ensured because of the acute arm size of two metres and optimised house inside the booths.
Special torch for extreme spaces
Each valve body is equipped with a cone guide which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily difficult. For manual welding, the welder is unable to see the weld seam and as an alternative must rely on their experience. Even for automated welding, these areas are very uncommon. EWM was solely in a place to accept this job because they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a special development with a very small torch head and unconventionally long torch neck. Of course, the particular software needed to be tailored to accommodate this unusual design: as a end result of dilution between the parent metal and the armouring must be as low as possible, solely slightly vitality is used. This ensures secure heat dissipation despite the acute welding torch dimensions.
Secure welding outcomes by way of outlined parameters
As the elements had been rotationally symmetrical, it was straightforward to teach the elements; teaching is all the time based on the identical programs. Even new elements could be welded automatically rapidly. Users merely need to set the radius, variety of passes and the geometric dimensions of the surfaced components and the robot control will take care of the remainder. The desired welding result’s all the time guaranteed because the welding process is defined with all of its parameters. The high quality may additionally be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was initially designed and supposed for one particular application, Schroeder is already pondering of recent ideas and uses. Schroeder want to try out some of the numerous welding procedures that are included within the Titan XQ welding machine as standard. This will enable to further optimise different sorts of surfaced components. Schroeder are additionally trying to increase and improve the vary of welding tasks.
There are lots of of Schroeder Valves put in in plants in southern Africa defending belongings at corporations like Sasol, Eskom, Mondi and Sappi to name a few. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full repair and reconditioning amenities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact sales@valve.co.za, www.valve.co.za or cellphone 011 397 2833 or 0861 103 103 to study more.
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