SCHROEDER – NEW WELDING ROBOT FOR PUMP PROTECTION VALVES

Automated เกจวัดแรงดันดิจิตอลราคา of rotationally symmetrical elements
Everything from a single supply – it‘s more than only a advertising promise! Over 50 drawings of varied components served as the premise for the automation solution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s elements did have one factor in widespread, they have been all rotationally symmetrical. This was the starting point for welding machine manufacturer EWM in their mission to develop a customized automation resolution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used all over the world for transporting liquids utilizing centrifugal pumps. Their areas of software embrace refineries, energy plants and nuclear plants, within the transport of liquefied natural gas (LNG), in addition to in offshore rigs. They are also used all through the chemical and manufacturing trade (steelworks, pulp, sugar, distilleries) and in the utilisation of renewable energies.
Different sizes – one application.
The goal is to weld all pump safety valve components routinely. These valves are related on to the pumps and ensure continuous operation of the pumps to stop them working dry or being broken by cavitation during minimum circulate conditions. The pump safety valve is largely made up of the valve body and the cone, which strikes contained in the valve physique. The sealing surfaces between the valve body and the cone have to be absolutely air and watertight. This is the one means to ensure proper functioning of the pump safety valve for decades to come back. Normally, these elements are made using low-cost construction steel DIN 1.0460. The sealing surfaces are strengthened with stainless-steel DIN 1.4370. This course of was previously carried out manually, however, due to both the shortage of fine welders and growing high quality assurance requirements, automation of this step was essential. The inside diameter of the valve our bodies and the cone diameters had been between 32 mm and 400 mm. The components being moved additionally differed vastly in weight, starting from a few hundred grams to two and a half tonnes. But all of the components had one thing in frequent: they were all rotationally symmetrical, making them perfect for an automatic 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 became clear that only a robot system would fit the invoice when it got here to automating this particular course of. Having to deal with so many alternative half sizes was a cause for concern. Large elements require a large welding positioner. These, nevertheless, cannot provide the dynamics required for the smaller elements. This rapidly gave rise to the thought of three processing stations: one giant L-positioner with tilting perform for the massive valve our 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 parts. The peak of the constructing was additionally a particular challenge. The components had to have the power to be positioned on the benches with the crane. The crane hook, nonetheless, was solely approximately three metres excessive – extraordinarily small for an industrial application. To guarantee accessibility whereas guaranteeing extraction, either the extraction hood or the system benches were made to be cellular. The robotic was fitted in an especially small sales space within the centre between the three stations. This booth additionally includes both the facility source 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 robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations at all needed positions can be ensured because of the intense arm size of two metres and optimised area contained in the booths.
Special torch for extreme spaces
Each valve body is provided with a cone guide which is welded from above. With an inside diameter of just 32 mm, entry is extraordinarily difficult. For handbook welding, the welder is unable to see the weld seam and as an alternative should rely on their expertise. Even for automated welding, these spaces are very unusual. EWM was solely able to settle for this job because they manufacture the torches, emphasising the importance of the welding torch for this utility. The welding torch for Schroeder Valves is a particular building with a very small torch head and unconventionally long torch neck. Of course, the special application needed to be adapted to accommodate this unusual design: as a end result of dilution between the parent steel and the armouring needs to be as low as attainable, only somewhat vitality is used. This ensures secure warmth dissipation despite the extreme welding torch dimensions.
Secure welding outcomes by way of outlined parameters
As the elements have been rotationally symmetrical, it was simple to show the parts; teaching is all the time based mostly on the identical programs. Even new elements may be welded mechanically rapidly. Users simply need to set the radius, variety of passes and the geometric dimensions of the surfaced parts and the robot control will deal with the rest. The desired welding result’s always assured as a result of the welding procedure is outlined with all of its parameters. The high quality can be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was originally designed and meant for one particular application, Schroeder is already thinking of latest ideas and uses. Schroeder wish to try out a few of the varied welding procedures which are included in the Titan XQ welding machine as standard. This will allow to further optimise completely different kinds of surfaced parts. Schroeder are additionally looking to broaden and enhance the vary of welding duties.
There are tons of of Schroeder Valves installed in plants in southern Africa defending assets at corporations like Sasol, Eskom, Mondi and Sappi to name a couple of. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full repair and reconditioning services are available 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 extra.
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