SCHROEDER – NEW WELDING ROBOT FOR PUMP PROTECTION VALVES

Automated surfacing of rotationally symmetrical elements
Everything from a single supply – it‘s more than only a marketing promise! Over 50 drawings of assorted parts served as the idea for the automation solution developed by EWM for pump protection valve producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s components did have one factor in frequent, they have been all rotationally symmetrical. This was the start line for welding machine producer EWM in their mission to develop a custom automation solution tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used all round the world for transporting liquids using centrifugal pumps. Their areas of software embrace refineries, energy plants and nuclear vegetation, within the transport of liquefied pure gasoline (LNG), as properly as in offshore rigs. They are additionally used all through the chemical and manufacturing industry (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one application.
The purpose is to weld all pump protection valve parts routinely. These valves are connected on to the pumps and ensure continuous operation of the pumps to forestall them working dry or being broken by cavitation during minimal move situations. The pump protection valve is essentially made up of the valve physique and the cone, which moves inside the valve body. The sealing surfaces between the valve body and the cone have to be absolutely air and watertight. This is the one way to make sure correct functioning of the pump safety valve for decades to come back. Normally, เกจวัดแรงดันน้ำดิจิตอล are made utilizing low-cost development steel DIN 1.0460. The sealing surfaces are reinforced with stainless steel DIN 1.4370. This process was previously performed manually, nevertheless, due to each the scarcity of good welders and growing quality assurance requirements, automation of this step was essential. The internal diameter of the valve our bodies and the cone diameters have been between 32 mm and four hundred mm. The parts being moved additionally differed vastly in weight, starting from a few hundred grams to two and a half tonnes. But the entire parts had one thing in frequent: they have been all rotationally symmetrical, making them good 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 only a robot system would fit the bill when it got here to automating this explicit course of. Having to take care of so many alternative half sizes was a cause for concern. Large elements require a big welding positioner. These, nevertheless, can’t provide the dynamics required for the smaller parts. This shortly gave rise to the concept of three processing stations: one giant L-positioner with tilting operate for the large 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 parts. The top of the building was also a specific challenge. The components had to be able to be placed on the benches with the crane. The crane hook, however, was solely roughly three metres high – extremely small for an industrial software. To guarantee accessibility while guaranteeing 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 sales space additionally consists of each the power source 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 robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations in any respect essential positions can also be ensured due to the extreme arm size of two metres and optimised house inside the booths.
Special torch for excessive spaces
Each valve physique is provided with a cone information which is welded from above. With an inside diameter of simply 32 mm, entry is extremely difficult. For เกจวัดแรงดูด , the welder is unable to see the weld seam and as a substitute must rely on their experience. Even for automated welding, these spaces are very unusual. EWM was only capable of accept this job because they manufacture the torches, emphasising the importance of the welding torch for this application. The welding torch for Schroeder Valves is a special development with a particularly small torch head and unconventionally long torch neck. Of course, the special application had to be tailored to accommodate this uncommon design: as a end result of dilution between the mother or father metallic and the armouring must be as little as potential, only a little vitality is used. This ensures safe heat dissipation despite the intense welding torch dimensions.
Secure welding outcomes by way of outlined parameters
As the elements have been rotationally symmetrical, it was easy to teach the parts; teaching is all the time primarily based on the same packages. Even new parts can be welded automatically rapidly. Users merely have to set the radius, variety of passes and the geometric dimensions of the surfaced parts and the robotic management will deal with the remainder. The desired welding result is at all times assured as a end result of the welding process is outlined with all of its parameters. The high quality may additionally be confirmed retrospectively as all welding parameters are continuously monitored and recorded. Even although the system was initially designed and intended for one specific application, Schroeder is already thinking of recent concepts and makes use of. Schroeder wish to try out a variety of the various welding procedures that are included in the Titan XQ welding machine as commonplace. This will enable to additional optimise completely different kinds of surfaced elements. Schroeder are additionally seeking to increase and enhance the range of welding duties.
There are hundreds of Schroeder Valves installed in crops in southern Africa defending assets at firms like Sasol, Eskom, Mondi and Sappi to call a few. Sulzer & KSB routinely use Schroeder valves to protect their pumps. Full restore 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 phone 011 397 2833 or 0861 103 103 to learn more.
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