Description:“APH COLD END BASKET MODULAR FILLING MACHINE”

TECHNICAL FIELD

[0001] The present invention relates to an Air Preheater (APH) module machine for a Thermal Power Plant. More particularly, the present invention relates to an APH cold end basket filling in module machine.
BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention.
[0003] An Air preheater (APH) is used in thermal power station/industrial applications to extract heat from flue gas leaving boiler/furnace and to transfer the heat to the entering combustion air through heat transfer elements. The basket modules are made with diaphragm plate, stay plate with different segment fabricated with two chambers. One end of the basket module is a hot end chamber and another one is cold end chamber. The APH modules are rotating for the heating of the heating elements. The primary air passing through heating elements is used to heat the air.
[0004] The size of the modules depends on the power plant rating, eg. 250MW or 800 MW. 24 modules form one APH. The module assembly contain two chambers, a hot end chamber and a cold end chamber. Each module is filled with baskets of different types, viz. A,B,C,D,E, F, G, H and I depending on the location in the module assembly from the centre to the periphery of the APH. The APH baskets are made with a number of heating elements.
[0005] The heating elements are rolled in two assembly lines and are later filled into the module assembly after being dipped in the Rust Prev entive [RP] Oil. The dipped baskets are then moved to basket filling area and by using EOT crane the hot end chamber of the assembly is filled with the baskets of types A to I from the top.
[0006] While the hot end baskets are filled from the top using a crane, the cold end chamber has entry at the front end and needs to be filled by pushing the baskets into the chamber. Around 28 cold end baskets are required per module and are needed to be filled in horizontal position, inside the module.
[0007] Totally 1152 cold end basket are filled in one APH assembly machine. The cold end baskets heights are increased from 300mm to 1000mm due to SCR (Selective Catalytic Reduction). Height of the cold end baskets increased to 1000mm so that the weight is also increased from 500kg to 800kg. Heavy baskets are not able to push inside the module by using a bar or a rod.
[0008] Module Cold End Basket filling was historically, a job requiring man power of eight for pushing the cold end Basket into the module cold end chamber. More recently, pushing the cold end basket was done by battery operated platform truck using rear pushing. This is still highly risky and unsafe practice.
[0009] The shop floor would be slippery due to the baskets dipped in RP Oil and the platform truck is operated in rear while the feedback of filling would be a sudden bump and may lead to slipping.
OBJECTS OF THE DISCLOSURE
[0010] Some of the objects of the present disclosure, which at least have one embodiment herein satisfy, are listed herein below.
[0011] It is an object of the invention to design a APH module cold end basket filling machine which reduces the cycle time and safe operation of module filling.
[0012] It is another objective of the invention to design a module CE basket filling machine to increase the productivity of the thermal plant.
[0013] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.

SUMMARY
[0014] This summary is provided to introduce concepts related to an APH cold end basket filling in module machine. The concepts are further described below in a detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0015] The present invention is related to an APH cold end basket modular filing machine. The machine comprises of a first housing system, comprising: a tray extending longitudinally from a front end; a rotary to linear motion convertor coupled to a rotor for pushing/pulling the tray linearly forward and backward; a first frame provided at the front end to mount the tray from one end and connected to the rotary to linear motion convertor for pushing/pulling the tray; a geared motor connected to the motion converter as a motion source. The machine further comprises of a second housing system separated from the first housing system by a distance and comprising: a stationary stand having a rear end and a front end configured to receive a basket at the rear end and guide the basket to a destination from the first end; a second frame at the rear end of the stand for receiving other end of the tray; wherein the first and second frame are movable in the first and second housing system respectively to facilitate push or pull of the tray in the forward or backward direction, respectively.
[0016] In an embodiment of the present invention, the rotary to linear motion convertor comprises of a rack and pinion.
[0017] In an another embodiment of the present invention, the first housing system comprises of a lamp stand to enhance illumination throughout the APH cold end basket modular filing machine.
[0018] In an another embodiment of the present invention, the first housing system comprises of a control panel having a plurality of limit switches to control the geared motor.
[0019] In an another embodiment of the present invention, the first housing system comprises of plurality of guards to protect the APH cold end basket modular filling machine from damage.
[0020] In an another embodiment of the present invention, the plurality of guards comprises of a pinion guard, a flange guard and a tail guard.
[0021] In an another embodiment of the present invention, the first housing system comprises of lifting hooks for movement of the APH cold end basket modular filling machine with a crane.
[0022] In an another embodiment of the present invention, a plurality of guide bearings are placed around the first housing system to ease movement of the tray guide.
[0023] In an another embodiment of the present invention, the stationary stand in the second housing system comprises roller bearing for facilitation of forward and backward motion of the tray and motion of the basket.
[0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0025] The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
[0026] Figure 1 illustrates an isometric view of the Air Preheater and Baskets, in accordance with an embodiment of the present invention;
[0027] Figure 2 illustrates an isometric view of the first housing system of the APH basket filling machine, in accordance with an embodiment of the present invention;
[0028] Figure 3 illustrates a side view of the APH basket filling machine with the first housing system and a second housing system, in accordance with an embodiment of the present invention;
[0029] Figure 4 illustrates an isometric view of the stationary stand, in accordance with an embodiment of the present invention;
[0030] Figure 5 illustrates a top view of the APH basket filling machine, in accordance with an embodiment of the present invention;
[0031] Figure 6 illustrates a top view of the stationary stand, in accordance with an embodiment of the present invention;
[0032] Figure 7 illustrates a lamp stand with illumination source in accordance with an embodiment of the present invention;
[0033] Figure 8 illustrates a limit switch in accordance with an embodiment of the present invention;
[0034] Figure 9 illustrates a tool box compartment in accordance with an embodiment of the present invention;
[0035] Figure 10 illustrates a control push buttons compartment in accordance with an embodiment of the present invention;
[0036] Figure 11 illustrates cold end basket filling before coming in contact with the APH basket filling machine in accordance with an embodiment of the present invention; and
[0037] Figure 12 illustrates a practical use of the APH basket filing machine in accordance with an embodiment of the present invention.
[0038] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0039] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such detail as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[0040] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the principles of the present subject matter and are included within its scope.
Exemplary Implementations
[0041] Figure 1 illustrates an isometric view of an Air Preheater (APH) 100 and a number of baskets 102, in accordance with an embodiment of the present invention. The figure 1 depicts the top, front and side views of the APH 100 and the number of baskets 102. The number of baskets 102 need to be pushed horizontally inside the APH 100 to fill it during the APH 100 manufacturing process. The varying sizes and shapes of the number of baskets 102 can also be appreciated from the figure 1.
[0042] Figure 2 illustrates an isometric view of a first housing system 200 of APH basket filling machine 300, in accordance with an embodiment of the present invention. The first housing system 200 comprises of a tray 201 placed on a stand 1 extending longitudinally from a front end 203. The first housing system 200 further comprises of a rotary to linear motion convertor coupled to a rotor 2 for pushing/pulling the tray 201 linearly forward and backward. The linear motion convertor may comprise of a rack 4 and a pinion 3.
[0043] Furthermore, the first housing system 200 comprises of a first frame 5 provided at the front end 203 to mount the tray 201 from one end and connected to the rotary to linear motion convertor for pushing/pulling the tray 201. Additionally, a geared motor 11 is connected to the motion converter as a motion source. The geared motor consists of bearing 19.
[0044] A lamp 6 is also attached to the first housing system 200 to enhance illumination throughout the APH cold end basket modular filling machine 300. Further, a control panel 12 is associated with the first housing system 200. The control panel 12 consists of a number of limit switches 7, 8 to control the geared motor 11.
[0045] A number of guards are present on the first housing system 200 to protect the APH cold end basket modular filing machine 300 from damage. The number of guards may consist of a pinion guard 13, a flange guard 14 and a tail guard 15. Furthermore, the first housing system 200 comprises of lifting hooks 17 for movement of the APH cold end basket modular filing machine 300 with a crane.
[0046] Also, to ease movement of the tray guide 201, a number of guide bearings 18 are placed around the first housing system 200. A motor stand 10 is further depicted in the figure 2 to hold the rotary to linear motion convertor.
[0047] Figure 3 illustrates a side view of the APH basket filling machine 300 with the first housing system and a second housing system, in accordance with an embodiment of the present invention. As can be observed from figure 3, the APH basket filling machine 300 comprises of the first housing system 200 and the second housing system 202. The second housing system 202 is separated from the first housing system 200 by a distance to form the APH basket filing machine 300.
[0048] The second housing system 202 comprises of a stationary stand 16 having a rear end and a front end. The stationary stand 16 is configured to receive a basket 102 at the rear end and guide the basket to a destination from the first end. The second housing system 202 further comprises of a second frame 5 at the rear end of the stationary stand 16 for receiving other end of the tray 201.
[0049] The first frame 5 and the second frame 5 are movable in the first 200 and the second housing 202 respectively to facilitate push or pull of the tray in the forward or backward direction respectively. The stationary stand 16 in the second housing system 202 comprises of a roller bearing for facilitation of forward and backward motion of the tray 201 and motion of the basket 102.
[0050] Figure 4 illustrates an isometric view of the stationary stand 16, in accordance with an embodiment of the present invention. As described in the preceding paragraphs, the stationary stand 16 is having a rear end and a front end configured to receive a basket 102 at the rear end and guide the basket 102 to a destination from the first end. Further, as can be observed from the figure 4, a second frame 5 is attached at the rear end of the stand 16 for receiving other end of the tray 201.
[0051] Figure 5 illustrates a top view of the APH basket filling machine 300, in accordance with an embodiment of the present invention.
[0052] Figure 6 illustrates a top view of the stationary stand 16, in accordance with an embodiment of the present invention.
[0053] Figure 7 illustrates the lamp stand 6 with illumination source in accordance with an embodiment of the present invention. As described in the preceding paragraphs, the lamp stand 6 is used to enhance illumination throughout the APH cold end basket modular filling machine 300.
[0054] Figure 8 illustrates a limit switch 7 in accordance with an embodiment of the present invention. The limit switch 7 is placed in the control panel 12 to control the geared motor 11.
[0055] Figure 9 illustrates a tool box compartment in accordance with an embodiment of the present invention.
[0056] Figure 10 illustrates a control push buttons compartment 12 in accordance with an embodiment of the present invention.
[0057] Figure 11 illustrates a cold end basket 102 filling before coming in contact with the APH basket filling machine 300 in accordance with an embodiment of the present invention. The figure 11 depicts the filling of cold end baskets 102 wherein a long ladder 1002 is attached onto a platform truck 1004. The platform truck 1004 is operated in reverse direction by an operator and the basket 102 is pushed into the cold end chamber in the APH 100. The visibility of operator is very less to operate the platform truck 1004, leading to more cycle time and rework of job. Also slipping due to leaked oil and sudden bumps when the basket hits the end make it an unsafe operation.
[0058] Figure 12 illustrates a practical use of the APH basket filing machine 300 in accordance with an embodiment of the present invention. The figure 12 depicts the practical use of the machine 300 to fill the baskets 102 in the cold end chamber of an APH 100. The oil dipped baskets 102 are loaded by the crane onto the stationary stand 16 and the baskets 102 are pushed into the APH 100 using the ladder 1002 attached to the motor driven tray 201. The rotatory motion is converted into linear motion to push basket 102 inside the APH 100 using hand control remote.
[0059] This machine 300 avoids the operation of a platform truck 1004 in reverse direction to push the cold end basket 102 into APH 100 cold end chamber which is unsafe and requires man power to continually observe and operate the platform truck 1004 to prevent accidents. Eliminating use of platform truck 1004 leads to man power savings and increases safety by avoiding slippage of platform truck 1004 due to oil spilling. The Platform truck 1004 breakdowns due to hitting while pushing the baskets 102 in reverse operation is also avoided.
Advantages-
[0060] The APH module cold end basket filling machine 300 reduces the cycle time and safe operation of module filling.
[0061] The APH module cold end basket filling machine increases the productivity of the thermal plant.
[0062] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
[0063] It will be further appreciated that functions or structures of a number of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present invention contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the invention, and other dimensions or geometries are possible. In addition, while a feature of the present invention may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present invention. The present invention also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.
, Claims:We Claim
1. An Air Preheater (APH) cold end basket modular filling machine (300) comprising:
a first housing system (200), comprising:
a tray (201) extending longitudinally from a front end (203);
a rotary to linear motion convertor coupled to a rotor (2) for pushing/pulling the tray (201) linearly forward and backward;
a first frame (5) provided at the front end to mount the tray (201) from one end and connected to the rotary to linear motion convertor for pushing/pulling the tray (201);
a geared motor (11) connected to the motion converter as a motion source;
a second housing system (202) separated from the first housing system (200) by a distance and comprising:
a stationary stand (16) having a rear end and a front end configured to receive a basket (102) at the rear end and guide the basket to a destination from the first end;
a second frame (5) at the rear end of the stationary stand (16) for receiving other end of the tray (201);
wherein the first (5) and second frame (5) are movable in the first housing system (200) and second housing system (202) respectively to facilitate push or pull of the tray (201) in the forward or backward direction, respectively.
2. The APH cold end basket modular filling machine (300) as claimed in claim 1, wherein the rotary to linear motion convertor comprises of a rack (4) and pinion (3).
3. The APH cold end basket modular filling machine (300) as claimed in claim 1 or in claim 2, wherein the first housing system (200) comprises of a lamp stand (6) to enhance illumination throughout the APH cold end basket modular filling machine (300).
4. The APH cold end basket modular filling machine (300) as claimed in any one of the claims 1 to 3, wherein the first housing system (200) comprises of a control panel (12) having a plurality of limit switches (7, 8) to control the geared motor (11).
5. The APH cold end basket modular filling machine (300) as claimed in any one of the claims 1 to 4, wherein the first housing system (200) comprises of plurality of guards to protect the APH cold end basket modular filling machine (300) from damage.
6. The APH cold end basket modular filling machine (300) as claimed in claim 5, wherein the plurality of guards comprises of a pinion guard (13), flange guard (14) and a tail guard (15).
7. The APH cold end basket modular filling machine (300) as claimed in any one of the claims 1-6, wherein the first housing system (200) comprises of lifting hooks (17) for movement of the APH cold end basket modular filling machine (300) with a crane.
8. The APH cold end basket modular filling machine (300) as claimed in any one of the claims 1-7, wherein a plurality of guide bearings (18) are placed around the first housing system (200) to ease movement of the tray guide.
9. The APH cold end basket modular filling machine (300) as claimed in any one of the claims 1-8, wherein the stationary stand (16) in the second housing system (202) comprises roller bearing for facilitation of forward and backward motion of the tray (201) and motion of the basket (102).
Dated this 19th day of March, 2024

SOMA RANI MISHRA
IN/PA – 1159
L. S. DAVAR & CO.,