Automated surfacing of rotationally symmetrical elements

Everything from a single source – it‘s more than just a advertising promise! Over 50 drawings of various components served as the basis for the automation solution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s parts did have one factor in widespread, they had been all rotationally symmetrical. This was the begin line for welding machine producer EWM in their mission to develop a custom automation solution tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of software embody refineries, power vegetation and nuclear plants, within the transport of liquefied pure gas (LNG), as well as in offshore rigs. They are additionally used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
เพรสเชอร์เกจ is to weld all pump protection valve components automatically. These valves are connected on to the pumps and guarantee steady operation of the pumps to forestall them running dry or being damaged by cavitation during minimal flow situations. The pump safety valve is basically 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. pressure gauge is the one method to make sure proper functioning of the pump protection valve for many years to come back. Normally, these parts are made using low-cost development metal DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This course of was beforehand carried out manually, however, as a outcome of both the shortage of fine welders and rising quality assurance requirements, 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 also differed vastly in weight, starting from a couple of hundred grams to 2 and a half tonnes. But the entire elements had one factor in frequent: they had been all rotationally symmetrical, making them perfect 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 quickly grew to become clear that only a robotic system would match the bill when it got here to automating this specific course of. Having to cope with so many different half sizes was a trigger for concern. Large parts require a large welding positioner. These, nevertheless, cannot provide the dynamics required for the smaller elements. This rapidly gave rise to the concept of three processing stations: one large L-positioner with tilting operate for the large 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 top of the constructing was additionally a selected challenge. The elements had to have the flexibility to be placed on the benches with the crane. The crane hook, nonetheless, was solely approximately three metres excessive – extraordinarily small for an industrial software. To assure accessibility whereas ensuring extraction, both the extraction hood or the system benches were made to be mobile. The robotic was fitted in an extremely small sales space within the centre between the three stations. This sales space also contains each the ability 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 a hundred iD in all three stations at all essential positions can be ensured thanks to the extreme arm length of two metres and optimised house contained in the cubicles.
Special torch for excessive areas

Each valve physique is equipped with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extraordinarily tough. For handbook welding, the welder is unable to see the weld seam and instead must depend on their expertise. Even for automated welding, these areas are very uncommon. EWM was only able to settle for this job as a result of they manufacture the torches, emphasising the significance of the welding torch for this application. The welding torch for Schroeder Valves is a particular building with a very small torch head and unconventionally long torch neck. Of course, the particular software had to be adapted to accommodate this uncommon design: as a outcome of dilution between the mother or father metallic and the armouring needs to be as low as potential, only slightly energy is used. This ensures safe warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes via defined parameters

As the components were rotationally symmetrical, it was simple to teach the elements; instructing is all the time based mostly on the identical programs. Even new parts may be welded routinely shortly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced parts and the robotic management will deal with the rest. The desired welding result is all the time guaranteed because the welding procedure is outlined with all of its parameters. The high quality can additionally be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and meant for one particular software, Schroeder is already pondering of latest ideas and uses. Schroeder want to try out a variety of the varied welding procedures that are included in the Titan XQ welding machine as commonplace. This will enable to additional optimise totally different sorts of surfaced components. Schroeder are additionally looking to increase and enhance the vary of welding duties.
There are tons of of Schroeder Valves put in in vegetation in southern Africa protecting assets at firms like Sasol, Eskom, Mondi and Sappi to name a quantity of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning facilities 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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