SCHROEDER – NEW WELDING ROBOT FOR PUMP PROTECTION VALVES

Automated surfacing of rotationally symmetrical parts
Everything from a single source – it‘s greater than just a advertising promise! Over 50 drawings of varied elements served as the premise for the automation solution developed by EWM for pump safety valve manufacturer, Schroeder Valves GmbH in Germany. All of the main specialist’s components did have one thing in widespread, they have been all rotationally symmetrical. This was the start line for welding machine producer EWM of 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, energy plants and nuclear vegetation, in the transport of liquefied pure gasoline (LNG), as well as in offshore rigs. They are additionally used throughout the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one utility.
The purpose is to weld all pump safety valve elements mechanically. These valves are related directly to the pumps and ensure steady operation of the pumps to stop them operating dry or being broken by cavitation throughout minimum move conditions. The pump protection valve is essentially made up of the valve physique and the cone, which moves contained in the valve body. The sealing surfaces between the valve physique and the cone have to be absolutely air and watertight. This is the only means to make sure proper functioning of the pump protection valve for decades to return. Normally, these elements are made using low-cost development steel DIN 1.0460. The sealing surfaces are strengthened with stainless steel DIN 1.4370. This process was beforehand performed manually, nevertheless, as a outcome of both the scarcity of excellent welders and rising high quality assurance necessities, automation of this step was crucial. The internal diameter of the valve bodies and the cone diameters had been between 32 mm and 400 mm. The components being moved also differed vastly in weight, starting from a couple of hundred grams to 2 and a half tonnes. But the entire elements had one factor in widespread: they had been all rotationally symmetrical, making them excellent for an automated process. With this as a beginning point, EWM was in a place to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations
It quickly turned clear that only a robotic system would fit the invoice when it got here to automating this specific course of. Having to cope with so many various half sizes was a cause for concern. Large components require a big welding positioner. These, nonetheless, cannot present the dynamics required for the smaller parts. This quickly gave rise to the idea 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 3rd station with a system bench with out positioners for some other elements. The top of the constructing was additionally a selected challenge. The parts had to have the power to be placed on the benches with the crane. The crane hook, however, was only approximately three metres excessive – extremely small for an industrial application. To guarantee accessibility whereas ensuring extraction, either the extraction hood or the system benches had been made to be cellular. The robotic was fitted in an extremely small sales space within the centre between the three stations. This sales space also includes each the facility source and a Titan XQ. These are positioned behind the L-positioner on the giant processing station. The Rob 5 drive 4X wire feeder mounted on the robotic arm ensures secure wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations at all necessary positions can be ensured due to the intense arm length of two metres and optimised area contained in the cubicles.
Special torch for excessive areas
Each valve physique is supplied with a cone information which is welded from above. With เกจวัดแรงดัน4บาร์ of just 32 mm, entry is extraordinarily difficult. For handbook welding, the welder is unable to see the weld seam and instead must depend on their expertise. Even for automated welding, these spaces are very unusual. EWM was only 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 building with a particularly small torch head and unconventionally lengthy torch neck. Of course, the special software had to be tailored to accommodate this uncommon design: as a end result of dilution between the father or mother steel and the armouring must be as little as possible, only a little energy is used. This ensures secure warmth dissipation despite the extreme welding torch dimensions.
Secure welding results through defined parameters
As the components had been rotationally symmetrical, it was simple to show the components; teaching is all the time based mostly on the identical packages. Even new parts may be welded mechanically quickly. Users merely should set the radius, number of passes and the geometric dimensions of the surfaced elements and the robot control will care for the remainder. The desired welding result is all the time guaranteed because the welding procedure is outlined with all of its parameters. The quality can be proven retrospectively as all welding parameters are repeatedly monitored and recorded. Even although the system was initially designed and intended for one specific application, Schroeder is already considering of latest concepts and makes use of. Schroeder would like to try out a number of the various welding procedures which are included in the Titan XQ welding machine as normal. This will allow to additional optimise different kinds of surfaced parts. Schroeder are additionally seeking to increase and improve the vary of welding duties.
There are lots of of Schroeder Valves installed in crops in southern Africa protecting assets at corporations like Sasol, Eskom, Mondi and Sappi to call a number of. Sulzer & KSB routinely use Schroeder valves to guard 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 be taught more.
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