Description:
A SYSTEM FOR AUTOMATED LUBRICATION OF INNER WALL OF PIERCED BILLET IN POWDERED FORM
FIELD OF INVENTION
[0001] The present disclosure relates to a method of manufacturing of seamless steel tubes .The present invention particularly relates to an automated spray system for lubricating the inner wall surface of pierced billet in powdered form during the manufacturing processes of seamless steel tubes.
BACKGROUND OF INVENTION
[0002] In manufacturing of seamless steel tubes, round billets heated in rotary hearth furnace to the required hot forming temperature are converted into hollow blooms by rolling spirally over a plug in piercing process. The hollow blooms thus formed are transferred to the mandrel inserting and crimping station. In the crimping station the one end of the hollow is crimped on to the mandrel bar and transferred to push bench. In push bench, the pinion driven rack with pusher bar pushes the mandrel bar with hollow bloom through the non-driven three roller die cages to form shells.
[0003] In pushing process, the hollow is allowed to elongate along the mandrel length while axial and shear forces are applied by the rollers. DC drive is used to drive the hollow with mandrel at constant speed to control the required metallurgical and dimensional parameters of the output. To regulate the load requirement of the drive sufficient lubrication is to be maintained between the mandrel and the inner surface of hollow.
[0004] The conventional stem for manufacturing seamless steel tubes presents several drawbacks. It heavily relies on manual labor and lacks automation, leading to variations in product quality and increased labor costs. Precise control over metallurgical and dimensional parameters is limited due to its dependence on DC drive and constant speed. Maintenance challenges arise from the need for consistent lubrication, potentially causing wear and downtime. The system's energy inefficiency, variability in product quality, limited product range, safety concerns, reliability issues, and environmental impact further hinder its competitiveness in the market.
[0005] Therefore, it is quite evident that all of the above disclosures has drawbacks and thereby the process with automated equipment is crucial for efficiency, quality, and sustainability. challenges collectively hinder system efficiency and reliability. Thus there is a pressing need to achieve the same.
OBJECTS OF THE INVENTION
[0006] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0007] It is an object of the present subject matter to overcome the aforementioned and other drawbacks existing in the prior art systems and methods.
[0008] It is a principal object of the present subject matter to introduce a system for applying lubricant in powdered form using a pneumatic system, eliminating potential irregularities in lubrication.
[0009] It is another significant object of the present subject matter to propose the system integrating the lubrication system into the manufacturing process streamlines operations, reducing interruptions and enhancing overall efficiency.
[0010] It is another significant object of the present subject matter to propose the system with Higher-level PLC automation empowers operators to monitor and adjust the lubrication process, enhancing flexibility and adaptability.
[0011] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taking into consideration with accompanied drawings in which preferred embodiments of the present subject matter are illustrated.
SUMMARY OF THE INVENTION
[0012] This summary is provided to introduce the concept of a system for automated lubrication of inner wall of pierced billet in powdered form. The concepts are further described below in the 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.
[0013] The present invention discloses a system for automated lubrication of inner wall of pierced billet in powdered form. The system comprising of an air inlet for the supply of the air into the system , a storage unit for the storage and dispersion of the powdered lubricant into the system, a stir valve connected to the air inlet and storage unit to control the flow of air from the air inlet and lubricant from the storage unit , a powder valve connected to the stir valve and the air valve to control the flow of the lubricant to the system, a spray valve connected to the powder valve and the air valve to dispense the lubricant to the hollow ; a stopper connected to the spray valve. The sensor is the Hot Metal Detector(HMD) sensor which senses the pierced billet at the stopper. The lubricant level is monitored using an ultrasonic sensor inside the storage unit. Both the signals are communicated to the control unit The chipping hammer along with the solenoid valve forms the stir valve as a whole. The control unit regulate and control the operation of the lubrication.
[0014] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit the scope of the present subject matter.
[0015] 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
[0016] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which
[0017] Fig. 1 illustrates the schematic diagram of a system for automated lubrication of inner wall of pierced billet in powdered form in accordance with an embodiment of the present disclosure;
[0018] Fig 2 illustrates the schematic diagram of a pneumatic system for automated lubrication spray system in accordance with an embodiment of the present disclosure; and
[0019] Fig. 3 illustrates the schematic diagram of a field illustration of automated lubrication of inner wall of pierced billet in powdered form in accordance with an embodiment of the present disclosure.
[0020] 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 INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS
[0021] A few aspects of the present disclosure are explained in detail below with reference to the various figures. Example implementations are described to illustrate the disclosed subject matter, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations of the various features provided in the description that follows.
[0022] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0023] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the “invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0024] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.
[0025] Various embodiments are further described herein with reference to the accompanying figures. It should be noted that the description and figures relate to exemplary embodiments and should not be construed as a limitation to the subject matter of the present disclosure. It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the subject matter of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the subject matter of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof. Yet further, for the sake of brevity, operation or working principles pertaining to the technical material that is known in the technical field of the present disclosure have not been described in detail so as not to unnecessarily obscure the present disclosure.
EXEMPLARY EMBODIMENT
[0026] The present invention discloses a system for automated lubrication of inner wall of pierced billet in powdered form Fig. 1 illustrates the schematic diagram of a system for automated lubrication of inner wall of pierced billet in powdered form in accordance with an embodiment of the present disclosure. The system comprising of an air inlet (102) for the supply of the air into the system , a storage unit(104) for the storage and dispersion of the powdered lubricant into the system, a stir valve(106) connected to the air inlet(102) and storage unit(104) to control the flow of air from the air inlet (102) and lubricant from the storage unit(104) , a powder valve(108) connected to the stir valve(106) and the air inlet(102) to control the flow of the lubricant to the system, a spray valve(110) connected to the powder valve(108) and the air inlet(102) to dispense the lubricant to the hollow ; a stopper(112) connected to the spray valve(110). A chipping hammer (105) along with a solenoid valve (118) forms the stir valve (106) .The sensor (114), is the Hot Metal Detector(HMD) sensor which senses the pierced billet at the stopper. The lubricant level is monitored using an ultrasonic sensor inside the storage unit. Both the signals are communicated to the control unit (122). The control unit (122) regulate and control the operation of the lubrication. A plurality of hand operated valves (116) are configured for controlling the flow of lubricant in the system (100) and the chipping hammer (105) along with the solenoid valve (118) make up the stir valve (106) configured for the transmission of the powdered lubricant into the system (100).
[0027] The air inlet (102) supplies compressed air to the system. The compressed air is often used to assist in the dispersal of powdered lubricant.
[0028] The storage unit (104) serves as a reservoir for storing and dispensing the powdered lubricant. It holds a supply of the lubricant that can be drawn upon when needed.
[0029] The chipping hammer (105) is used to create a vibration action so that the lubricant in powder form is transmitted through the pipe when it operates. The manual actuator of the chipping hammer (105) is forced so that it operated on the action of the single solenoid valve and allows the powder lubricant to fall through the pipe due to gravity and vibration action of the chipping hammer (105).
[0030] The chipping hammer (105) along with the solenoid valve (118) forms the stir valve (106) as a whole. Additionally, the system incorporates a plurality of hand-operated valves (116), each positioned strategically throughout the system (100) to control the flow of lubricant. These hand-operated valves (116) allow for manual control over the lubrication process, enabling adjustments and fine-tuning to meet the lubrication needs of various components within the system.
[0031] The stir valve (106) is connected to both the air inlet (102) and the storage unit. It controls the flow of air from the air inlet (102) and the flow of lubricant from the storage unit. The stirring of the lubricant with air may be necessary to maintain an even consistency of the powdered lubricant.
[0032] The powder valve (108) is linked to the stir valve (106) and the air valve. It controls the flow of the lubricant from the storage unit (104) into the system. It helps regulate the amount of lubricant being dispensed.
[0033] The spray valve (110) is connected to both the powder valve (108) and the air valve. Its primary function is to dispense the lubricant into the hollow of the steel tube. This component ensures that the lubricant is applied precisely where needed.
[0034] The stopper (112) is a hydraulic element used to stop the moving pierced billet. A provision for the outlet of the spray valve (110), is provided near the stopper(112).
[0035] The sensor (114), is the Hot Metal Detector(HMD) sensor which senses the pierced billet at the stopper. The lubricant level is monitored using an ultrasonic sensor inside the storage unit. Both the signals are communicated to the control unit (122). The sensor (114) is configured within the system to monitor various parameters such as lubricant levels, equipment conditions (such as temperature or pressure), or environmental factors (such as humidity). This data is valuable for ensuring efficient and effective lubrication.
[0036] The hot metal detector fetches feedback from the sensor (114) and is used to monitor the temperature and condition of the steel tube within the manufacturing process. This feedback is crucial for making real-time adjustments to the lubrication process. The hot metal detector detects the infrared radiation which is emitted by a hot material. When the material with a temperature above a threshold is detected it provides a switching signal. It is mounted on a support frame (126) and transmits the switching signal to the input output modules of the control unit (122).
[0037] The control unit (122) receives data from the hot metal detector and other sensor and uses this data to regulate and control the operation of the lubrication system (100) making adjustments to the flow of lubricant, air, or other parameters to optimize lubrication The signal from the hot metal detector is transmitted to the filed input output module of the control unit (122) at the nearest control desk. The CPU is located in the panel room and the input output module of the control unit (122) are distributed across the plant with PROFIBUS interconnection.
[0038] Fig 2 illustrates the schematic diagram of a pneumatic system for automated lubrication spray system in accordance with an embodiment of the present disclosure. The system (100) comprises of pneumatic system which is used to dispense the powdered lubricant from the storage unit (104) and spray into the hollow. The operation of the pneumatic system (100) is controlled via higher level PLC control unit (122) with feedback taken from the hot metal detector sensor (114) in the existing process. The whole system is integrated into the present process with control of the system (100) given to the operator via SCADA. The system (100) comprises of pneumatic system which is used to dispense the powdered lubricant from the storage unit (104) and spray into the hollow (120). The operation of the pneumatic system (100) is controlled via higher level PLC control unit (122) with feedback taken from the hot metal detectors in the existing process. The whole system is integrated into the present process with control of the system (100) given to the operator by the control unit (122) via SCADA and ensures uniform distribution of the lubricant along the length of the hollow leading better lubrication between mandrel and the hollow (120).
[0039] Fig. 3 illustrates the schematic diagram of a field illustration of automated lubrication of inner wall of pierced billet in powdered form in accordance with an embodiment of the present disclosure.
[0040] Step1: On completion of the billet piercing operation, the solenoid valve (118) to the chipping hammer (105) is energized. As soon as the chipping hammer (105) operation is completed (time bound) the main valve (108) is energized to transmit the collected powder into the connecting pipe. Both the actions are executed while the hollow bloom (120) is transmitted to the aligning conveyer (124).
[0041] Step2: The hollow bloom (120) is placed on the aligning conveyer (124) after piercing.
[0042] Step3: The hollow bloom (120) is transferred in the aligning conveyer (124) and stops at the stopper (112). The hollow bloom (120) at the stopper (112) is detected by the sensor (114) and signal is transmitted to the control unit (122).
[0043] Step4: On the sensor (114) signal trigger the spray valve (110) is energized to spray the lubricant into the inner wall surface of the hollow bloom (120). Duration of the spray valve operation can be entered by the operator in the SCADA

ADVANTAGES OF THE INVENTION
[0044] The proposed system for automated lubrication has the following advantages over the contemporary system:
• Consistent Lubrication: Ensures consistent and uniform application of powdered lubricant, eliminating irregularities associated with manual lubrication.
• Streamlined Operations: Integration into the manufacturing process reduces interruptions and enhances overall efficiency.
• Enhanced Operator Control: Higher-level PLC automation empowers operators to monitor and adjust the lubrication process in real time, improving flexibility and adaptability.
• Optimized Equipment Performance: Consistent and precise lubrication contributes to improved equipment performance, reducing wear and extending operational life.
• Reduced Material Waste: Minimizes lubricant waste, reducing costs and environmental impact.
WORKING OF INVENTION
[0045] The present invention of automated spray system for lubricating pierced billets in powdered form is effectively employed within the steel tube manufacturing industry. This system ensures precise and consistent lubrication of the inner wall surfaces, contributing to the efficiency and longevity of machinery. Its automation and feedback mechanisms reduce manual intervention, streamline operations, and optimize equipment performance in the production of seamless steel tubes.
[0046] The above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[0047] Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0048] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[0049] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
, Claims:We Claim:
1. A system for automated lubrication of inner wall of pierced billet in powdered form (100), the system (100) comprising:
an air inlet (102) for the supply of the air into the system (100);
a storage unit (104) for the storage and dispersion of the powdered lubricant into the system (100);
a chipping hammer (105) connected to the storage unit for creating vibration for the transmission of the powdered lubricant into the system (100);
a stir valve (106) connected to the air inlet (102) and storage unit (104) to control the flow of air from the air inlet (102) and lubricant from the storage unit (104);
a powder valve (108) connected to the stir valve (106) and the air inlet (102) to control the flow of the lubricant to the system;
a spray valve (110) connected to the powder valve (108) and the air inlet (102) to dispense the lubricant to the hollow;
a stopper (112) connected to the spray valve (110) to halt / control the flow of lubricant from the spray valve (110);
a chipping hammer (105) along with a solenoid valve (118) forms the stir valve (106) ;
a sensor (114) is a Hot Metal Detector(HMD) sensor configured to sense the pierced billet at the stopper(112), mounted on a support frame(126) wherein the hot metal detector sensor fetches the feedback to a control unit(122) .
2. The system (100) as claimed in the claim 1, wherein a plurality of hand operated valves (116) are configured for controlling the flow of lubricant in the system (100).
3. The system (100) as claimed in the claim 1, wherein a solenoid valve (118) is connected to the chipping hammer (105) configured for the transmission of the powdered lubricant into the system (100).
4. The system (100) as claimed in the claim 1, wherein the control unit (122) regulates and controls the operation of the lubrication