DESC:FIELD OF THE INVENTION:

[0001] This invention relates to the field of spray valves used in High Pressure Turbine Bypass system. More particularly the invention relates to a device for holding the stems during the process of Heat treatment in the Production hierarchy of spray valves stem.

BACKGROUND OF THE INVENTION:

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] During manufacturing of Spray Valves there are several stages starting from Machining, drilling, welding, Heat treatment of components/body of valves, Lapping, assembly, Testing etc. Heat treatment process involves in the stems which comes in the body of spray valves (Types: E22S, E32S, E45S). During process of HT the stems needs to be dipped in salt bath at a particular temperature to achieve the desired material property. For dipping the stem to the salt bath, it was required to drill the material and hang it with ties inside the furnace. Additional material length and machining process were required to make the drill in the stem and later removing of excess material from the stem which takes more effort and increases the cycle time in the production line.

[0004] The traditional method of the manufacturing process of stems involved drilling a hole in the designated excess material area of the stem, followed by suspending the stem inside the furnace using tie steel ropes. After heat treatment, the excess portion was cut, removed, and subsequently subjected to machining and grinding. This traditional method required additional material length and extensive machining efforts, thereby increasing production cycle time and overall labour.

[0005] Therefore, to optimize the process, the need arose for a more efficient method of holding the stem during heat treatment. The newly introduced SIGMA HOOK eliminates the necessity for extra material by utilizing an existing groove in the stem’s design for suspension. This innovation significantly reduces material wastage, eliminates unnecessary machining, and streamlines the heat treatment process for spray valve stems.

[0006] Thus, the present invention proposes a flexible hanging solution which takes less effort and decreases the cycle time in the production line.

OBJECTS OF THE INVENTION:

[0007] An object of the invention is to provide a device for holding the stem to hang it down to the furnace during the heat treatment process in the manufacturing processes of stems used in spray valves.

[0008] Another object of the present invention is to propose a device for holding the stem to hang it down to the furnace during the heat treatment process so that excess material which comes in the stem can be avoided and proper dipping of entire stem inside the salt bath for heat treatment can be achieved during manufacturing process of stems used in spray valves.

[0009] Yet another object of the present invention is to provide a device for holding the stem and to hang it down to the furnace during the heat treatment process so that it may reduce the material wastage, eliminates the unnecessary machining process, and streamlines the heat treatment process and decreases the cycle time for the manufacturing of the spray valve stems.

[0010] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.

SUMMARY OF THE INVENTION:

[0011] One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus/composition and a method as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be part of the claimed disclosure.

[0012] According to the present invention, there is provided a device for holding a stem to hang it down to the furnace during the heat treatment process in the manufacturing processes of stems used in spray valves.

[0013] In an aspect, the device for holding the stem during the heat treatment process comprising of a plate having a lower portion and an upper portion; a lock pin provided at the lower portion of the plate is to hold the stem firmly inside the plate; a fastener attached to the upper portion of the plate; and a ring mounted on the fastener; wherein the plate is configured to receive the stem from an opening provided at the lower portion of the plate and the stem is detachably attached to the upper portion of the plate through the fastener. The device is made up of any material including metal and non-metal.

[0014] In an aspect, the fastener is comprises of a bolt. Further, the lock pin is replaceable so as to accommodate the stem into the plate of the device.

[0015] In an aspect, the stem has groove through which it is attached to the bolt. The opening provided at the lower portion of the plate is having substantially semi-ellipse profile.

[0016] In another aspect, the device along with the stem can be hanged in a furnace through the ring

[0017] 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.

[0018] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.

[0019] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING:

[0020] The illustrated embodiments of the subject matter will be best 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 processes that are consistent with the subject matter as claimed herein, wherein:-

[0021] Figure 1 illustrates the side view of the device, according to the embodiments of the present disclosure.

[0022] Figure 2 illustrates the perspective view of the device, according to the embodiments of the present disclosure.

[0023] Figure 3 illustrates the combined assembled view of sigma hook device along with the stem, according to the embodiments of the present disclosure.

[0024] The figures depict embodiments of the present subject matter for the purposes of illustration only. One skilled in the art will readily 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. Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals should be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE PRESENT INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWING:

[0025] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have been shown by way of example in the figures and will be described below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternative falling within the scope of the disclosure.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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.

[0030] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover a non-exclusive inclusion, such that a device, system, assembly that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system or device proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or device.

[0031] The present subject matter discloses a device for holding the stems during the process of heat treatment in the production hierarchy of spray valves. According to the disclosure, the inventive device will help in hanging the stem through the SIGMA HOOK with the support of groove made in the stem surface.

[0032] Figure 1 illustrates the side view of the invented sigma hook device according to the present invention. The device (100) is used for holding the stem and to hang it down to the furnace during the heat treatment process in the manufacturing processes of stems which is used in the spray valves. The device (100) is comprising of a plate (1) that have a lower portion (11) and an upper portion (12), a lock pin (4) which is provided at the lower portion (11) of the plate (1) wherein the lock pin (4) is used to hold the stem firmly inside the plate (1), a fastener (2) which is attached to the upper portion (12) of the plate (1), and a ring (3) mounted on the fastener (2).

[0033] Figure 2 illustrates the perspective view of the sigma hook device according to the present invention. The device (100) comprising of a plate (1) that have a lower portion (11) and an upper portion (12), wherein the plate (1) is configured to receive the stem (5) from an opening (11a) provided at the lower portion (11) of the plate (1). The stem (5) when placed inside the plate (1) may be detachably attached to the upper portion (12) of the plate (1) through the fastener (2). The fastener (2) holds the stem (5) through groove present in the stem's design for suspension.

[0034] In an embodiment, the device (100) along with the stem (5) may be hanged in the furnace through the ring (3) for the heat treatment process. Figure 3 that illustrates the combined and assembled view of sigma hook device (100) along with the stem, wherein the device along with the stem may be hanged in the furnace during the heat treatment process of stems.

[0035] The fastener (2) comprises of a bolt. The lock pin (4) is replaceable, i.e., it may be removed from the device (100) before the stem (5) is placed in the plate (1) and once the stem (5) is accommodated in the plate (1), the lock pin (4) may be placed back again at its original position to hold the accommodated stem (5) firmly into the plate (1) of the device (100). The stem (5) has groove in its design through which it is connected to the bolt (2) present at the upper portion (12) of the plate (1).

[0036] According to the present invention, the opening (11a) provided at the lower portion (11) of the plate (1) may have substantially semi-ellipse profile, however, it can be of any shape. Though, the device (100) may be made up of any material, including metal or non-metal, there is no limitation on whatsoever material is used for the device. However, generally, the device is made up of iron or steel so that it may withstand with the high temperature present in the furnace during the heat treatment process.

[0037] The earlier process involved in the manufacturing processes of Stems included the steps of drilling of a hole in the stem in the excess area that is provided for the same and then hanging the stem with tie steel ropes inside the furnace. Later the process involved cutting and removal of the excess portion and then machining and grinding of the stem. In this process, additional material length and machining process were required to make the drill in the stem and later removing of excess material from the stem, which takes more effort and increases the cycle time in the production line. Therefore, there is need of a device for holding the stem for hanging it down to the furnace aroused.

[0038] The new device helps in avoiding requirement of excess material in the stem by usage of SIGMA HOOK for hanging the stem through the groove, which is in the design also thereby reducing the excess material usage and extra work that needed in the process of Heat treatment of spray valve stems.

[0039] The earlier process involved drilling, hanging, cutting, machining, and grinding, that increases production time and complexity. However, the present invention uses the sigma hook device which allows direct suspension without drilling, cutting, or additional machining, that significantly reducing cycle time. The earlier process required complex handling and additional steps before and after heat treatment. However, the new sigma hook device enables easy and direct suspension of the stem inside the furnace, which improves operational efficiency.

[0040] The conventional method of manufacturing the stems requires the drilling a hole in the stem which weakened its structure and introduced potential stress points. However, as per the present invention, by using an existing groove for suspension, the stem retains its original structural strength, which leads to improved durability and reliability of the stems. In addition, the drawback of the earlier processes is that it requires more usage of material and additional machining which increases the production costs, however, the present invention eliminates the material wastage and reduces the machining steps also, which lead to cost savings and a more sustainable manufacturing process of stems.

Advantages of Invention

[0041] Additionally, the novel sigma hook device is having the following advantages:

a) It eliminates the requirement of excess material,
b) It reduces the manufacturing effort and cycle time of the manufacturing process,
c) It enhances the efficiency in heat treatment process,
d) Improved the structural integrity of the stem, and
e) As it eliminates the material wastage and reduces the machining steps, it leads to cost savings and a more sustainable manufacturing process.

WORKING OF THE INVENTION

[0042] The present invention utilizing the SIGMA HOOK that streamlines the process of heat treatment for spray valve stems in an industrial setting makes use of an existing groove in the stem’s design for suspension, which eliminates the need for extra material and drilling. The SIGMA HOOK securely holds the stem through its groove, ensuring quick and stable suspension inside the furnace. This also prevents movement which ensures uniform heat treatment. The suspended stems undergo heat treatment inside the furnace without the risk of loosening or misalignment, improving the efficiency and uniformity of hardening. Since there is no drilled hole, the structural integrity of the stem is maintained, preventing any weak points. In addition, since no extra material is used, the stems can be directly taken for the next processing stage, which in turn reduces handling time, material wastage, and production effort.

Industrial Benefits and Field Application

• Faster production cycle as multiple stems can be quickly suspended and processed.
• Reduced labour and machining cost as no extra material is used or removed.
• Better quality control since the structural integrity of the stem remains intact.
• Energy savings due to the optimized handling process, leading to improved furnace loading efficiency.

TEST RESULT

[0043] The disclosed sigma hook device (100) for holding the stem (5) and to hang it down to the furnace during the heat treatment process in the manufacturing processes of stems used in spray valves has given the tremendous results when comparing to the existing conventional method of manufacturing processes of stems used in spray valves. The test results showing the great difference between the present sigma hook and the existing prior methods is given in Table below:

Parameters Existing Prior Methods (Drilled Hole & Steel Rope Method) Present Invention using SIGMA HOOK Method Improvement
(in %)
Material Usage 55 mm (extra material length required for drilling) no extra length required for material 20% of material saved
Cycle Time (per batch of stem) 25.5 hrs 18.5 hrs 27.5% faster
Machining Process Steps 4 steps (drilling, suspension, cutting, grinding) 2 steps (direct suspension, heat treatment) 50% fewer steps
Labor Requirement 2 workers 1 worker 50% reduction
Furnace Loading Efficiency 80% capacity used 100% capacity used 25% improvement
Energy Consumption (kWh per batch) 120 kWh 100 kWh 16.7% savings

[0044] Therefore, it may be significant that when applied in industrial manufacturing settings, the present invention significantly enhances efficiency, cost-effectiveness, and quality control in the heat treatment of spray valve stems. It further eliminates unnecessary steps, reduces material wastage, and simplifies the overall production process.

[0045] 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.

[0046] 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.

[0047] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particulars claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogues to “at least one of A, B and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B”.

[0048] The above description does not provide specific details of 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.

[0049] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present 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.

[0050] 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.

[0051] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.
,CLAIMS:We Claim:
1. A device (100) for holding a stem (5) during a heat treatment process, the device (100) comprising of:
- a plate (1) having a lower portion (11) and an upper portion (12);
- a lock pin (4) provided at the lower portion (11) of the plate (1) is to hold the stem (5) firmly inside the plate (1);
- a fastener (2) attached to the upper portion (12) of the plate (1); and
- a ring (3) mounted on the fastener (2);
wherein,
the plate (1) is configured to receive the stem (5) from an opening (11a) provided at the lower portion (11) of the plate (1),
the stem (5) is detachably attached to the upper portion (12) of the plate (1) through the fastener (2),

2. The device (100) as claimed in claim 1, wherein the fastener (2) comprises of a bolt.

3. The device (100) as claimed in claim 1, wherein the lock pin (4) is replaceable to accommodate the stem (5) into the plate (1) of the device.

4. The device (100) as claimed in claim 1-3, wherein the stem (5) has groove through which it is attached to the bolt (2).

5. The device (100) as claimed in claim 1, wherein the opening (11a) is having substantially semi-ellipse profile.

6. The device (100) as claimed in claim 1-5, wherein the device is made up of material including metal and non-metal.

7. The device (100) as claimed in claims 1-6, wherein the device (100) along with the stem (5) can be hanged in a furnace through the ring (3).