Automated surfacing of rotationally symmetrical elements

Everything from a single source – it‘s greater than just a advertising promise! Over 50 drawings of varied elements 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 frequent, they had been all rotationally symmetrical. This was the start line for welding machine manufacturer EWM in their mission to develop a custom automation answer tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum move valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of utility include refineries, energy plants and nuclear plants, in the transport of liquefied pure gasoline (LNG), as well as in offshore rigs. They are also 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 automatically. These valves are connected directly to the pumps and guarantee steady operation of the pumps to stop them operating dry or being broken by cavitation during minimum circulate circumstances. The pump safety valve is largely made up of the valve body and the cone, which strikes contained in the valve body. The sealing surfaces between the valve physique and the cone have to be completely air and watertight. This is the one method to ensure proper functioning of the pump safety valve for many years to return. Normally, these parts are made using low-cost building metal DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This process was beforehand carried out manually, nonetheless, due to each the shortage of fine welders and growing high quality assurance necessities, automation of this step was crucial. The inside diameter of the valve bodies and the cone diameters had been between 32 mm and 400 mm. The elements being moved also differed vastly in weight, ranging from a quantity of hundred grams to two and a half tonnes. But all of the parts had one factor in widespread: they have been all rotationally symmetrical, making them perfect for an automatic course of. 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 turned clear that only a robotic system would fit the invoice when it came to automating this specific course of. Having to cope with so many different part sizes was a cause for concern. Large elements require a big welding positioner. These, however, cannot provide the dynamics required for the smaller components. This rapidly gave rise to the idea of three processing stations: one large L-positioner with tilting operate for the massive valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a 3rd station with a system bench with out positioners for any other components. The height of the constructing was also a specific problem. The components had to have the ability to be positioned on the benches with the crane. The crane hook, nevertheless, was only approximately three metres high – extremely small for an industrial software. To assure accessibility while making certain extraction, either the extraction hood or the system benches had been made to be mobile. The robotic was fitted in an especially small sales space within the centre between the three stations. This booth additionally includes both the ability source and a Titan XQ. These are positioned behind the L-positioner at the large processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures secure wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations at all necessary positions is also ensured due to the intense arm size of two metres and optimised house contained in the cubicles.
Special torch for excessive spaces

Each valve body is provided with a cone information which is welded from above. With an inside diameter of just 32 mm, entry is extremely difficult. 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 uncommon. EWM was solely capable of accept this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this application. The welding torch for Schroeder Valves is a particular development with a very small torch head and unconventionally lengthy torch neck. Of course, the special utility needed to be tailored to accommodate this uncommon design: as a end result of dilution between the parent metal and the armouring must be as low as possible, only slightly energy is used. This ensures secure warmth dissipation despite the intense welding torch dimensions.
Secure welding outcomes through defined parameters

As the parts have been rotationally symmetrical, it was simple to teach the components; instructing is at all times based on the same packages. Even new components may be welded mechanically quickly. Users merely have to set the radius, number of passes and the geometric dimensions of the surfaced components and the robotic control will deal with the rest. เกจวัดแรงดัน desired welding result is all the time guaranteed as a result of the welding procedure is outlined with all of its parameters. The quality can be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was originally designed and meant for one specific application, Schroeder is already pondering of new ideas and uses. Schroeder wish to try out a few of the varied welding procedures which are included within the Titan XQ welding machine as commonplace. This will permit to further optimise different kinds of surfaced elements. Schroeder are additionally trying to increase and improve the range of welding duties.
There are lots of of Schroeder Valves installed in plants in southern Africa protecting assets at companies like Sasol, Eskom, Mondi and Sappi to name a number of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning facilities are available at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact sales@valve.co.za, www.valve.co.za or phone 011 397 2833 or 0861 103 103 to study more.
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