SCHROEDER – NEW WELDING ROBOT FOR PUMP PROTECTION VALVES

Automated compound gauge ราคา of rotationally symmetrical elements
Everything from a single supply – it‘s greater than just a advertising promise! Over 50 drawings of varied parts served as the basis for the automation resolution developed by EWM for pump protection valve manufacturer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one factor in frequent, they had been all rotationally symmetrical. This was the begin line for welding machine producer EWM in their mission to develop a customized automation solution tailor-made 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 software embody refineries, energy plants and nuclear vegetation, in the transport of liquefied natural gas (LNG), in addition to in offshore rigs. They are also used throughout the chemical and manufacturing trade (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. These valves are related directly to the pumps and guarantee steady operation of the pumps to forestall them running dry or being damaged by cavitation during minimum circulate situations. The pump safety valve is largely made up of the valve physique and the cone, which strikes inside the valve body. The sealing surfaces between the valve physique and the cone have to be completely air and watertight. This is the only way to make sure proper functioning of the pump safety valve for many years to come back. Normally, these components are made utilizing low-cost development metal DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This course of was beforehand performed manually, nonetheless, because of each the shortage of fine welders and rising high quality assurance requirements, automation of this step was essential. The inner diameter of the valve 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 number of hundred grams to two and a half tonnes. But the entire components had one thing in frequent: they have been all rotationally symmetrical, making them good for an automatic process. 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 solely a robot system would match the invoice when it came to automating this particular process. Having to cope with so many various half sizes was a trigger for concern. Large parts require a large welding positioner. These, nonetheless, can’t provide the dynamics required for the smaller elements. This quickly gave rise to the thought of three processing stations: one giant L-positioner with tilting perform for the big valve our bodies, one small turning/tilting positioner on a system bench for the small valve bodies, and a third station with a system bench without positioners for some other parts. The peak of the constructing was additionally a specific problem. 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 high – extremely small for an industrial software. To assure accessibility whereas making certain extraction, either the extraction hood or the system benches had been made to be cellular. The robotic was fitted in a particularly small sales space within the centre between the three stations. This booth also includes both the facility source 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 one hundred iD in all three stations at all needed positions is also ensured because of the intense arm size of two metres and optimised house contained in the cubicles.
Special torch for extreme areas
Each valve body is supplied with a cone guide which is welded from above. With an inside diameter of simply 32 mm, access is extraordinarily tough. For handbook welding, the welder is unable to see the weld seam and as an alternative should depend on their expertise. Even for automated welding, these areas are very unusual. EWM was solely able to 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 special construction with a particularly small torch head and unconventionally long torch neck. Of course, the special application needed to be tailored to accommodate this unusual design: as a result of dilution between the father or mother steel and the armouring must be as little as attainable, solely somewhat power is used. This ensures secure heat dissipation despite the intense welding torch dimensions.
Secure welding outcomes through outlined parameters
As the components had been rotationally symmetrical, it was simple to teach the elements; instructing is all the time based mostly on the identical programs. Even new components could be welded routinely quickly. Users simply need to set the radius, number of passes and the geometric dimensions of the surfaced components and the robot management will care for the remainder. The desired welding result is at all times assured because the welding process is defined with all of its parameters. The high quality can also be proven retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was initially designed and intended for one specific utility, Schroeder is already pondering of new ideas and makes use of. Schroeder would like to try out some of the numerous welding procedures which are included within the Titan XQ welding machine as normal. This will enable to additional optimise totally different sorts of surfaced components. Schroeder are also seeking to expand and improve the vary of welding tasks.
There are hundreds of Schroeder Valves put in in crops in southern Africa defending assets at firms like Sasol, Eskom, Mondi and Sappi to call a couple of. Sulzer & KSB routinely use Schroeder valves to protect 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 be taught more.
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