EFCO ROTAGO 24 Stationary Ball-Lapping Machine Instructions
- June 9, 2024
- EFCO
Table of Contents
ROTAGO 24 Stationary Ball-Lapping
Machine Instructions
With automatic lapping sequence
Stationary ball-lapping machine for ball workpieces of DN range of up to 600 mm (24‘‘), for simultaneously finishing balls and both metal sealing rings.
sample representation
EFCO ROTAGO 24 is a perfect tool for lapping-in ball valves ball and metal seal seats. ROTAGO 24 was designed for lapping different types of seal seats and balls, such as floating ball or trunnion mounted ball when the surface and the surface quality are extremely important.
The main features of this machine are:
- Choice between manual and automatic lapping mode
- Simultaneous lapping of the ball and both seal seats
- SIEMENS SIMATIC S7 controlled
- SIEMENS drive
- Timer with automatic shut-off
- Continuously variable control of drive speeds
- Independent speed control of individual drives
- Rotation direction of the drive changeable
- Integrated metering device for lapping oil for continuous dilution of the lapping mixture
- Ergonomically adjustable control panel
- Continuously variable pressure setting for contact pressure between valve seat and ball
- Collection tank for used lapping mixture
- Automatic lapping sequence in automatic mode
- Machining parameters selectable and adjustable for all machining ranges
- Multi-language user interface
- Usable as a polishing machine for balls to produce high-gloss surfaces
Technical data
| DN-range: | DN 200–600 (8”–24”) |
|---|---|
| Ball diameter: | Ø 300 mm to Ø 900 mm (12”–36”) |
| Max. ball weight: | approx. 1,500 kg (3,306.9 lbs.) |
| Dimensions (L x W x H): | approx. 3,000 mm x 2,800 mm x 2,000 mm (6,613.9 x |
6,172.9 x 4,409.2)
Power supply: 400 V (50/60 Hz)
(Please inquire if different customer-provided power supply required!)
Compressed air (network air): max. 6–7 bar (87–100 psi)
Recommended surface roughness and dimensional accuracy before lapping
| Ball dimensional accuracy: | ~ 0.02 mm |
|---|---|
| Surface roughness: | ~ Ra 0.4µm |
Description of function
The valve’s ball is clamped in the three-jaw chuck situated on the main
spindle by means of special holders. A rotating centre in the tailstock
supports the ball. The seal seats are clamped in special receptacles on a ball
joint in the secondary spindles. The base body of the ball joint has an
adjustable counterweight to keep the different sizes of seal seats in
horizontal position. The seal seats are pressed against the ball via pneumatic
cylinders. The entire unit of the secondary spindles is moved forward and
backward (oscillation) on a circular path around the centre of the ball by a
drive. The stroke of the forwards and backwards movement is adjustable. During
the lapping process an automatic dosing device ensures a continuous flow of
the lapping oil. The lapping paste is applied manually to the ball and seal
seats beforehand. Through the several different movements between the ball and
seal seats a precise surface shape of the ball and seal seats to each other is
created during the lapping process. This machining step provides a perfect
match between the ball and the seal seats.
Lapping programs for the respective DN ranges can be stored in the ROTAGO 24
control panel. This way lapping quality and processing time are exactly
reproducible for certain ball types and for quality assurance.
The operator is free to concentrate on other tasks after starting the lapping
cycle. Storage and administration of corresponding lapping programs can be
carried out in the password protected area of the control panel, e.g., by the
operator.
Following parameters are entered in the lapping programs for a respective DN range:
- Main spindle rotation speed
- Change of rotation direction of the main drive (clockwise, anti-clockwise) or change of rotation direction based on time or position (e.g., for lapping not the complete ball surface but only certain areas (ball-sectors)).
- Rotation speed of the auxiliary spindles
- Change of rotation direction of the auxiliary spindles (clockwise, anti-clockwise) and change of rotation direction based on sequence time
- Oscillation speed
- Contact pressure of the auxiliary spindles (intensity of surface treatment)
- Quantity of lapping oil (drip intensity)
- Total lapping time
Control Panel
All switches and display instruments required for operating the ROTAGO are clearly arranged in groups on the control panel.
The illustrations are examples, deviations are possible. / Right reserved to make technical changes. Rev.01B (07-2022)
Standard scope of delivery
| 1 pc. | Basic machine, complete (incl. chuck) |
|---|---|
| 1 pc. | Operating and tool accessories |
| 1 pc. | Operating instructions |
! Not included in the standard scope of delivery: Clamping devices for balls
and seat rings required for mounting on the machine. Provision. These can be
provided by the
customer or, after technical clarification, by EFCO.
Consumables included in scope of delivery
3 pcs| Lapping paste: boron carbide grain sizes 800, 1,200, 1,500 [0.5 kg (1.1
lbs.) each]
---|---
10 litres| Lapping oil
5 litres| Cleaning liquid
! Lapping agent for various balls and seat rings
We are happy to offer you additionally required lapping agents according to
your requirements:
- material or coating of the balls and seat rings,
- surface quality of the work pieces before lapping,
- desired surface quality of the work pieces after lapping.
The illustrations are examples, deviations are possible.
Right reserved to make technical changes. Rev.01B (07-2022)
Documents / Resources
| EFCO
ROTAGO 24 Stationary Ball-Lapping
Machine
[pdf] Instructions
ROTAGO 24, Stationary Ball-Lapping Machine, Ball-Lapping Machine, Stationary
Ball-Lapping, Ball-Lapping, Stationary Machine, Lapping
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