SCHROEDER – NEW WELDING ROBOT FOR PUMP PROTECTION VALVES

Automated เกจวัดแรงดันสูง of rotationally symmetrical parts
Everything from a single supply – it‘s more than just a advertising promise! Over 50 drawings of varied components served as the idea 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 frequent, they were all rotationally symmetrical. This was the place to begin for welding machine producer EWM in their mission to develop a custom automation resolution tailored to this multifaceted challenge.
Automatic Recirculation Valves / Minimum circulate valves from Schroeder Valves are used everywhere in the world for transporting liquids using centrifugal pumps. Their areas of utility embody refineries, power vegetation and nuclear crops, in the transport of liquefied pure fuel (LNG), in addition to in offshore rigs. เกจวัดแรงดันดิจิตอลราคา are also used throughout 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 parts routinely. These valves are related on to the pumps and ensure continuous operation of the pumps to forestall them working dry or being broken by cavitation throughout minimal flow circumstances. The pump safety valve is essentially made up of the valve body and the cone, which strikes inside the valve physique. The sealing surfaces between the valve body and the cone must be absolutely air and watertight. This is the one method to ensure correct functioning of the pump safety valve for decades to come. Normally, these elements are made using low-cost development metal DIN 1.0460. The sealing surfaces are reinforced with chrome steel DIN 1.4370. This process was previously performed manually, however, because of each the shortage of fine welders and growing high quality assurance necessities, automation of this step was essential. The inside diameter of the valve our bodies and the cone diameters have been between 32 mm and four hundred mm. The components being moved also differed vastly in weight, ranging from a number 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 good for an automated 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 soon grew to become clear that only a robotic system would match the bill when it got here to automating this specific process. Having to take care of so many different half sizes was a trigger for concern. Large elements require a large welding positioner. These, however, can not provide the dynamics required for the smaller components. This rapidly gave rise to the idea of three processing stations: one large L-positioner with tilting operate for the big 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 top of the constructing was additionally a specific problem. The components had to have the power to be positioned on the benches with the crane. The crane hook, nevertheless, was solely approximately three metres high – extraordinarily small for an industrial software. To guarantee accessibility while making certain extraction, either the extraction hood or the system benches were made to be cellular. The robotic was fitted in a particularly small booth in the centre between the three stations. This booth also consists of both the power source and a Titan XQ. These are positioned behind the L-positioner at 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 in any respect necessary positions can additionally be ensured because of the acute arm length of two metres and optimised area inside the booths.
Special torch for extreme spaces
Each valve physique is provided with a cone guide which is welded from above. With an inside diameter of just 32 mm, access is extremely tough. For manual welding, the welder is unable to see the weld seam and as a substitute should depend on their expertise. Even for automated welding, these areas are very uncommon. EWM was only able to accept this job as a outcome of they manufacture the torches, emphasising the importance of the welding torch for this software. The welding torch for Schroeder Valves is a special building with a particularly small torch head and unconventionally long torch neck. Of course, the special application needed to be adapted to accommodate this uncommon design: as a outcome of dilution between the father or mother metal and the armouring must be as little as possible, solely a little vitality is used. This ensures secure warmth dissipation regardless of the acute welding torch dimensions.
Secure welding results through defined parameters
As the elements were rotationally symmetrical, it was simple to show the elements; educating is at all times based on the same packages. Even new elements could be welded routinely shortly. Users simply should set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robot control will care for the remaining. The desired welding result is at all times guaranteed as a outcome of the welding process is outlined with all of its parameters. The quality can be confirmed retrospectively as all welding parameters are constantly monitored and recorded. Even although the system was initially designed and supposed for one particular utility, Schroeder is already considering of new concepts and makes use of. Schroeder would like to check out a few of the varied welding procedures that are included in the Titan XQ welding machine as normal. This will enable to further optimise different kinds of surfaced parts. Schroeder are additionally looking to broaden and enhance the range of welding duties.
There are lots of of Schroeder Valves put in in crops in southern Africa protecting property at companies like Sasol, Eskom, Mondi and Sappi to call a few. Sulzer & KSB routinely use Schroeder valves to guard their pumps. Full restore and reconditioning amenities 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 more.
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