Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of varied components 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 thing in frequent, they had been all rotationally symmetrical. This was the start line for welding machine producer EWM in their mission to develop a customized automation solution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used all over the world for transporting liquids utilizing centrifugal pumps. Their areas of utility embody refineries, power vegetation and nuclear vegetation, in the transport of liquefied pure gas (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The goal is to weld all pump protection valve elements automatically. ความหมายของเครื่องวัดความดัน are connected on to the pumps and guarantee steady operation of the pumps to stop them working dry or being broken by cavitation during minimum circulate situations. The pump safety valve is essentially made up of the valve body and the cone, which strikes 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 proper functioning of the pump safety valve for many years to come. Normally, these components are made using low-cost construction metal DIN 1.0460. pressure gauge หลักการ ทํา งาน sealing surfaces are reinforced with stainless-steel DIN 1.4370. This course of was beforehand performed manually, nevertheless, due to each the scarcity of fine welders and rising high quality assurance requirements, automation of this step was essential. The inner diameter of the valve our bodies and the cone diameters had been between 32 mm and four hundred mm. The components being moved also differed vastly in weight, starting from a couple of hundred grams to two and a half tonnes. But the entire parts had one thing in common: they had been all rotationally symmetrical, making them good 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 grew to become clear that solely a robotic system would fit the invoice when it came to automating this specific course of. Having to take care of so many alternative part sizes was a cause for concern. Large components require a big welding positioner. These, nevertheless, can’t present the dynamics required for the smaller elements. This quickly gave rise to the concept of three processing stations: one large L-positioner with tilting perform for the big 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 peak of the building was additionally a particular challenge. The parts had to find a way to be positioned on the benches with the crane. The crane hook, however, was only approximately three metres excessive – extraordinarily small for an industrial application. To guarantee accessibility while ensuring extraction, either the extraction hood or the system benches had been made to be cell. The robot was fitted in an especially small sales space within the centre between the three stations. This sales space additionally contains each the ability supply and a Titan XQ. These are positioned behind the L-positioner on the large 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 necessary positions is also ensured thanks to the acute arm length of two metres and optimised house inside the booths.
Special torch for extreme spaces
Each valve physique is provided with a cone information which is welded from above. With an inside diameter of just 32 mm, access is extremely troublesome. For manual welding, the welder is unable to see the weld seam and instead should depend on their experience. Even for automated welding, these areas are very uncommon. EWM was solely capable of settle for this job as a end result of they manufacture the torches, emphasising the significance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular development with a particularly small torch head and unconventionally long torch neck. Of course, the special software needed to be tailored to accommodate this unusual design: because dilution between the parent metallic and the armouring must be as little as potential, only a little energy is used. This ensures protected warmth dissipation regardless of the extreme welding torch dimensions.
Secure welding outcomes through outlined parameters
As the parts were rotationally symmetrical, it was simple to show the elements; teaching is always based on the same programs. Even new components can be welded routinely rapidly. Users merely need to set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robotic control will take care of the remainder. The desired welding result’s all the time assured as a outcome of the welding process is defined with all of its parameters. The quality can also be proven retrospectively as all welding parameters are constantly monitored and recorded. Even though the system was initially designed and supposed for one specific software, Schroeder is already thinking of recent ideas and uses. Schroeder want to try out a few of the various welding procedures which might be included within the Titan XQ welding machine as standard. This will allow to further optimise different sorts of surfaced components. Schroeder are additionally looking to broaden and improve the vary of welding tasks.
There are hundreds of Schroeder Valves put in in vegetation in southern Africa defending assets at corporations like Sasol, Eskom, Mondi and Sappi to name a quantity of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair 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 be taught extra.
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