Automated surfacing of rotationally symmetrical components

Everything from a single supply – it‘s greater than just a advertising promise! Over pressure gauge 10 bar of varied elements served as the premise for the automation resolution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s elements did have one thing in common, they were all rotationally symmetrical. This was the starting point for welding machine producer EWM in their mission to develop a customized automation resolution tailored to this multifaceted problem.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used everywhere in the world for transporting liquids utilizing centrifugal pumps. Their areas of application embody refineries, energy vegetation and nuclear vegetation, within the transport of liquefied natural fuel (LNG), as nicely as in offshore rigs. They are also used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one utility.
The goal is to weld all pump safety valve components routinely. These valves are related on to the pumps and guarantee steady operation of the pumps to prevent them working dry or being broken by cavitation during minimum flow conditions. The pump protection valve is essentially made up of the valve body and the cone, which strikes inside the valve body. The sealing surfaces between the valve physique and the cone have to be absolutely air and watertight. This is the one means to make sure correct functioning of the pump protection valve for decades to return. Normally, these elements are made utilizing low-cost building metal DIN 1.0460. The sealing surfaces are bolstered with stainless steel DIN 1.4370. This course of was beforehand carried out manually, however, as a result of each the shortage of excellent welders and growing quality assurance necessities, automation of this step was essential. The internal diameter of the valve bodies and the cone diameters were between 32 mm and four hundred mm. The elements being moved also differed vastly in weight, ranging from a few hundred grams to two and a half tonnes. But the entire components had one thing in widespread: they have been all rotationally symmetrical, making them excellent for an automated course of. With this as a place to begin, EWM was able to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It quickly grew to become clear that solely a robotic system would fit the invoice when it got here to automating this explicit process. Having to take care of so many different part sizes was a cause for concern. Large components require a large welding positioner. These, nevertheless, cannot provide the dynamics required for the smaller components. This quickly gave rise to the thought of three processing stations: one large L-positioner with tilting operate for the massive valve bodies, one small turning/tilting positioner on a system bench for the small valve our bodies, and a third station with a system bench with out positioners for another components. The height of the constructing was also a particular challenge. The parts had to find a way to be positioned on the benches with the crane. The crane hook, however, was solely roughly three metres high – extremely small for an industrial utility. To assure accessibility while making certain extraction, either the extraction hood or the system benches were made to be cellular. The robot was fitted in an especially small booth within the centre between the three stations. This booth also includes each the facility supply and a Titan XQ. These are positioned behind the L-positioner at the giant processing station. The Rob 5 drive 4X wire feeder mounted on the robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate a hundred iD in all three stations at all essential positions can additionally be ensured because of the acute arm size of two metres and optimised area contained in the cubicles.
Special torch for extreme spaces

Each valve body is supplied with a cone information which is welded from above. With an inside diameter of simply 32 mm, entry is extraordinarily tough. For guide welding, the welder is unable to see the weld seam and instead must depend on their expertise. Even for automated welding, these spaces are very unusual. EWM was solely capable of settle for this job as a outcome of they manufacture the torches, emphasising the significance of the welding torch for this application. 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 utility had to be adapted to accommodate this unusual design: because dilution between the mother or father steel and the armouring needs to be as low as potential, only slightly power is used. This ensures safe warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes through outlined parameters

As the parts have been rotationally symmetrical, it was simple to show the parts; instructing is at all times based on the identical applications. Even new parts may be welded mechanically rapidly. Users merely should set the radius, variety of passes and the geometric dimensions of the surfaced parts and the robot control will care for the remainder. The desired welding result is always assured as a end result of the welding procedure is defined with all of its parameters. The high quality can be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was originally designed and supposed for one particular application, Schroeder is already thinking of latest ideas and uses. Schroeder want to try out some of the various welding procedures which are included within the Titan XQ welding machine as commonplace. This will allow to further optimise completely different kinds of surfaced elements. Schroeder are additionally looking to increase and enhance the vary of welding duties.
There are hundreds of Schroeder Valves installed in vegetation in southern Africa protecting assets at companies like Sasol, Eskom, Mondi and Sappi to call a couple of. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore and reconditioning services can be found at Valve & Automation’s Secunda and Durban Valve Repair Centres. Please contact, or phone 011 397 2833 or 0861 103 103 to be taught more.
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