SCHROEDER – NEW WELDING ROBOT FOR PUMP PROTECTION VALVES

Automated surfacing of rotationally symmetrical parts

Everything from a single source – it‘s more 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 producer, Schroeder Valves GmbH in Germany. All of the leading specialist’s parts did have one thing in common, they had been all rotationally symmetrical. This was the begin line for welding machine producer EWM of their mission to develop a custom automation answer tailor-made to this multifaceted problem.
Automatic Recirculation Valves / Minimum flow valves from Schroeder Valves are used all over the world for transporting liquids using centrifugal pumps. Their areas of utility embrace refineries, energy plants and nuclear crops, in the transport of liquefied natural fuel (LNG), as nicely as in offshore rigs. They are also used all through the chemical and manufacturing business (steelworks, pulp, sugar, distilleries) and within the utilisation of renewable energies.
Different sizes – one software.
digital pressure gauge is to weld all pump protection valve elements mechanically. These valves are related on to the pumps and guarantee steady operation of the pumps to forestall them operating dry or being damaged by cavitation throughout minimum circulate situations. The pump protection valve is largely made up of the valve body and the cone, which moves contained in the valve physique. The sealing surfaces between the valve physique and the cone should be absolutely 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 parts are made utilizing low-cost building metal DIN 1.0460. The sealing surfaces are strengthened with stainless-steel DIN 1.4370. This course of was beforehand carried out manually, however, as a end result of both the scarcity of excellent welders and growing high quality assurance necessities, automation of this step was crucial. The inner diameter of the valve bodies and the cone diameters have been between 32 mm and four hundred mm. The elements being moved also differed vastly in weight, starting from a few hundred grams to 2 and a half tonnes. But all the elements had one factor in common: they had been all rotationally symmetrical, making them perfect for an automated process. With this as a place to begin, EWM was in a place to get the system planning ball rolling.
From Small to Big – Multiple Processing Stations

It soon became clear that only a robotic system would match the invoice when it came to automating this particular course of. Having to take care of so many alternative part sizes was a cause for concern. Large components require a large welding positioner. These, however, cannot provide the dynamics required for the smaller elements. This shortly gave rise to the idea of three processing stations: one giant L-positioner with tilting function 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 some other components. The peak of the constructing was additionally a particular challenge. The elements had to have the power to be placed on the benches with the crane. The crane hook, however, was solely roughly three metres high – extremely small for an industrial utility. To assure accessibility whereas guaranteeing extraction, both the extraction hood or the system benches have been made to be mobile. The robotic was fitted in an especially small sales space in the centre between the three stations. This sales space also contains each the ability 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 robot arm ensures safe wire feeding. Access to the Fanuc Arc Mate 100 iD in all three stations at all essential positions can be ensured thanks to the acute arm length of two metres and optimised area contained in the booths.
Special torch for extreme areas

Each valve physique is supplied with a cone information which is welded from above. With an inside diameter of just 32 mm, access is extraordinarily difficult. For handbook 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 in a place to settle for this job as a outcome 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 particular application had to be tailored to accommodate this uncommon design: as a outcome of dilution between the parent metal and the armouring must be as little as potential, only slightly vitality is used. This ensures secure heat dissipation despite the extreme welding torch dimensions.
Secure welding results through outlined parameters

As the components had been rotationally symmetrical, it was straightforward to show the parts; instructing is at all times primarily based on the same programs. Even new elements can be welded mechanically rapidly. Users simply have to set the radius, variety of passes and the geometric dimensions of the surfaced elements and the robot management will deal with the rest. The desired welding result’s at all times assured because the welding procedure is defined with all of its parameters. The high quality can be proven retrospectively as all welding parameters are continuously monitored and recorded. Even though the system was initially designed and supposed for one specific software, Schroeder is already pondering of latest ideas and makes use of. Schroeder would like to check out a number of the varied welding procedures which are included in the Titan XQ welding machine as normal. This will enable to further optimise different kinds of surfaced parts. Schroeder are additionally seeking to broaden and enhance the vary of welding tasks.
There are hundreds of Schroeder Valves installed in vegetation in southern Africa defending assets at companies like Sasol, Eskom, Mondi and Sappi to call 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 cellphone 011 397 2833 or 0861 103 103 to study extra.
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