Automated surfacing of rotationally symmetrical components
Everything from a single source – it‘s greater than just a marketing promise! Over 50 drawings of varied elements served as the basis for the automation resolution developed by EWM for pump safety valve producer, Schroeder Valves GmbH in Germany. All of the main specialist’s elements did have one factor in frequent, they had been all rotationally symmetrical. This was the place to begin for welding machine producer EWM of their mission to develop a custom 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 utility embody refineries, energy plants and nuclear vegetation, in the transport of liquefied natural gasoline (LNG), as well as in offshore rigs. They are additionally used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The aim is to weld all pump safety valve elements mechanically. These valves are linked directly to the pumps and guarantee continuous operation of the pumps to prevent them running dry or being damaged by cavitation during minimum move circumstances. The pump safety valve is largely made up of the valve physique and the cone, which strikes contained in the valve body. The sealing surfaces between the valve physique and the cone must be absolutely air and watertight. This is the one method to ensure correct functioning of the pump safety valve for many years to come. Normally, these components are made using low-cost development metal DIN 1.0460. The sealing surfaces are bolstered with chrome steel DIN 1.4370. This process was previously performed manually, nonetheless, as a end result of each the scarcity of fine welders and growing high quality assurance necessities, automation of this step was essential. The internal diameter of the valve our bodies and the cone diameters were between 32 mm and four hundred mm. The parts being moved also differed vastly in weight, ranging from a few hundred grams to 2 and a half tonnes. But all of the elements had one thing in frequent: they had been all rotationally symmetrical, making them perfect for an automated course of. With this as a beginning point, EWM was capable of get the system planning ball rolling.
From เกจแรงดันสูง to Big – Multiple Processing Stations
It quickly turned clear that only a robot system would fit the bill when it came to automating this explicit course of. Having to take care of so many various half sizes was a trigger for concern. Large elements require a big welding positioner. These, nevertheless, can not present the dynamics required for the smaller components. This rapidly gave rise to the concept of three processing stations: one massive L-positioner with tilting function for the massive valve 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 top of the constructing was additionally a specific problem. The elements had to have the ability to be placed on the benches with the crane. The crane hook, however, was only approximately three metres excessive – extraordinarily small for an industrial software. To assure accessibility whereas making certain extraction, both the extraction hood or the system benches have been made to be cell. The robotic was fitted in an especially small sales space in the centre between the three stations. This sales space also contains both the facility supply 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 safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations in any respect needed positions is also ensured because of the extreme arm length of two metres and optimised space contained in the cubicles.
Special torch for extreme areas
Each valve physique is supplied with a cone information which is welded from above. With an inside diameter of simply 32 mm, access is extremely difficult. For handbook welding, the welder is unable to see the weld seam and as a substitute must depend on their expertise. Even for automated welding, these spaces are very unusual. EWM was only in a position to settle for this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular development with a very small torch head and unconventionally lengthy torch neck. Of course, the particular utility needed to be adapted to accommodate this unusual design: as a result of dilution between the mother or father steel and the armouring must be as little as potential, only a little energy is used. This ensures safe warmth dissipation despite the intense welding torch dimensions.
Secure welding results by way of outlined parameters
As the elements were rotationally symmetrical, it was simple to teach the components; instructing is always based mostly on the same programs. Even new parts may be welded routinely quickly. Users merely have to set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robotic management will deal with the remainder. The desired welding result is all the time guaranteed as a end result of the welding process is defined with all of its parameters. The high quality can additionally be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was originally designed and supposed for one particular application, Schroeder is already pondering of latest concepts and uses. Schroeder want to try out a few of the various welding procedures that are included in the Titan XQ welding machine as commonplace. This will permit to additional optimise totally different kinds of surfaced elements. Schroeder are additionally trying to broaden and improve the range of welding tasks.
There are lots of of Schroeder Valves installed in plants in southern Africa protecting assets at corporations like Sasol, Eskom, Mondi and Sappi to name a number 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 sales@valve.co.za, www.valve.co.za or telephone 011 397 2833 or 0861 103 103 to study more.
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