Description:A BEARING ASSEMBLY DEVICE FOR HANDLING OF HEAVY ANGULAR BEARING

FIELD OF INVENTION:
[001] The invention is related to a bearing assembly device for handling of Heavy Angular Bearing.

BACKGROUND OF INVENTION/PRIOR ART:
[002] 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.

[003] Axial Profile Fans are used in Thermal power plants for ensuring air flow. Air flow is required for giving air for combustion of the fuel, movement of the fuel from the storage area to the furnace and also to remove the exhaust gases from the furnace to the atmosphere via the chimney. The heart of the Fan is Rotor which comprises of an Impeller Hub Assembly and Main Bearing Assembly which are coupled to each other. Drive is given to the Shaft of the Main Bearing Assembly via an Electric motor. Blades are attached on the Impeller assembly. Air is pulled from one end of the Impeller assembly to the other side.

[004] The Main Bearing Assembly mentioned before has a Shaft and Bearing Housing. Bearing Housing is a static part. Main Shaft is rotating part which is given drive with an Electric motor. In addition to it, Angular Bearings, Cylindrical Roller Bearings etc. are used. The assembly is conducted, axial and radial clearance is checked. The clearance should be optimum as per drawing to avoid extra vibrations while operation at site. After assembly and clearance checking, the job is taken for functional testing. This operation is done on a test bed which has an electric motor. It is assembled on the base clamps by bolting. Axial loads at the Non Drive end and Radial loads at both Shaft ends are applied synchronous as in site conditions. The Motor is coupled with the Shaft via coupling and it is rotated as per site recommended speed. The job is tested for four hours and it is tested for any leakages coming out through the seals in the assembly. In addition, temperature stability is checked i.e. while running the temperature of the bearing at both ends will be increasing and it should reach at a particular peak point and stabilize and maintain the same temperature. Suitable thermocouples are employed for measurement of these temperatures. There is also a lube oil system to cool the assembly while in operation.

[005] The assembly of Main Bearing assembly is done in a clean dust free room. As mentioned Angular Bearings and Cylindrical Roller Bearings are assembled along with the shaft. It is an Interference fit. The Bearing inside Races are to be heated in an induction heater and it is placed on to the shaft. Three artisans were involved in the assembly activity. They use industrial gloves to take the Bearing on to the Induction heater and after heating it is taken by the same person and assembled on to the shaft which is placed vertically in a pit. After the first side is completed, the shaft has to be reversed and kept vertically in the pit again. The second side bearing is also assembled in the same way. The issues encountered is the involvement of three persons, reversing of shaft vertically for assembly two times.

OBJECTS OF THE INVENTION:
[006] An object of the invention is to develop a Bearing assembly Device for handling of Heavy Angular Bearing which can hold the Bearing in stable condition and allow the Bearing to assemble on the Shaft of Main Bearing assembly suitably, which avoids reversal of the Shaft two times.

[007] Another object of the invention is to provide a Bearing assembly Device for handling of Heavy Angular Bearing, which obviates shortcomings of the prior art(s).

[008] One Another object of the invention is to develop a Bearing assembly Device for handling of Heavy Angular Bearing, which leads to reduction in the cycle time.

[009] Still another object of the invention is to develop a Bearing assembly Device for handling of Heavy Angular Bearing, which improves Safety.

[0010] Yet another object of the invention is to develop a Bearing assembly Device for handling of Heavy Angular Bearing, which is simple in construction.

[0011] 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:
[0012] 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.

[0013] According to this invention, there is provided a Bearing Assembly Device for Handling of Heavy Angular Bearing comprising of a clamp (1) connected to Eye bolt (2), wherein the clamp (1) is a single piece, which is having substantially U-section, in which the eye bolt (2) is fastened to the clamp (1).

[0014] The eye bolt (2) is fastened to the clamp (1) through a hole in the clamp (1).

[0015] The clamp (2) has one leg (1A) longer than other leg (1B) in parallel to each other, in which the longer leg has the hole for assembly of the clamp with the eye bolt (2).

[0016] The legs (1A,1B) are perpendicular to the base (1C) of the clamp.

[0017] The eye bolt (2) is threadingly fastened in the threaded hole of the clamp (2) for tight grip.

[0018] The present invention introduces a special clamp for lifting the Bearing in stable condition which can be employed for heating and assembly in the same position of Shaft Horizontally.

[0019] 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.

[0020] 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.

[0021] 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 DRAWINGS:
[0022] 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:

Figure 1 shows: Bearing assembly Device for handling of Heavy Angular Bearing according to the present invention.

Figure 2 shows: Old method of Bearing heating in Induction Heater.

Figure 3 shows: Old method of Bearing assembly on to the Shaft.

Figure 4 shows: New method of Lifting the bearing with the assembly Device of the invention.

Figure 5 shows: New method of bearing heating with the assembly Device in accordance with the invention.

Figure 6 shows: New method of bearing assembly on to the Main Shaft of invention.

[0023] The figures depict embodiments of the disclosure for 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.

DETAILED DESCRIPTION OF THE PRESENT INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS OF PREFERRED EMBODIMENTS:

[0024] 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.

[0025] The present invention makes a disclosure regarding a technology pertaining to an invention directing to a Bearing Assembly Device for Handling of Heavy Angular Bearing.

[0026] Now, reference may be made to figure 1. The device comprising of a clamp (1) connected to Eye bolt (2) so as to constitute said device of the present invention. The eye bolt (2) is fastened to the clamp (1) through a hole in the clamp (1). Thus, said clamp (1) is detachably connected to the eye bolt (2).

[0027] The clamp (1) is a single piece, which is having substantially U-section. It has one leg (1A) longer than other leg (1B) in parallel to each other. The longer leg has the hole for assembly of clamp with the eye bolt (2) as illustrated in the figure. Both the legs (1A,1B) are perpendicular to the base (1C) of the clamp.

[0028] The eye bolt (2) is threadingly fastened in the threaded hole of clamp for tight grip.

[0029] The device can be made of mild steel (MS) without restricting scope of the invention to the same. Thus, other materials readily apparent to a person skilled in the art are understood to be within purview of the invention.

[0030] Figure 2 & 3 shows the old method of assembly involving three persons. The bearing is assembled on to the Shaft which is kept vertically. After assembly the Shaft is reversed 180 degree. Second bearing is heated and assembled in the same method.

[0031] Figure 4,5 & 6 shows the new method of assembly. Instead of 3 persons 2 persons are involved. The device is used to hold the Bearing for induction heating for expansion and then for assembly on to the Main Shaft which is kept horizontally. Therefore, the Shaft reversal is avoided and manpower is reduced from 3 to 2. Cycle time is also reduced from 2 shifts to 1 shift.

Working of the invention

[0032] The Bearing Assembly Device made can hold the Bearing suitably and it can be lifted with Crane. Bearing can be moved with the crane via fastening the clamp to the Induction heater. After heating, the Bearing is moved in the same position with no reversal. The Main Shaft is kept horizontally. The expanded Bearing is assembled on to the Shaft. Immediate to it next bearing is lifted with the crane via clamp and it undergoes the same procedure.
Advantages of the Invention
- Instead of three-man power single person is employed to lift the bearing with crane and second person to guide the bearing on to the shaft;

- Reduction in Cycle time from two shifts to one shift per Main Bearing assembly;

- Simple in construction;

- Cost effective;

- User friendly.

Savings for a single Main Bearing assembly [An Examplary Embodiment]:

SL. No.
Labour Cost Savings per Assembly

1 Manhours = 2manpowerX 8hours + 1 manpower X
2 hours + 2 manpower X
8 hours

Dismantling with Fitters Heating with Welder Reassembly with Fitters
= 16+2+16 hours
= 34 hours
Hourly wage = Rs 525 / hour
Labor cost = Rs 34 X 525
= Rs. 17850
2

LPG Cost per Assembly

LPG Consumption = 5 kg
LPG Cost per kg = Rs. 60 / kg
LPG per assy = Rs 5 X 60
= Rs. 300

3

Crane cost per Assembly

Crane cost per hour = Rs. 160/hour
Crane duration involved = 4 hours
Total Crane cost = Rs. 160X 4
= Rs. 640

4

Consummables Wastage per Assembly

Loctite 5910 Amount wasted = 300 ml = 1 pack
Cost of Loctite 5910 (IM4513400700) = Rs. 3135/pack

5

Induction Heating cost per Assembly

Induction Heating duration per assembly = 6min = 0.1 hours
Induction Heating cost per Assembly = Rs. 1000 X 0.1
= Rs. 100

Total Cost per Assembly = Rs. 22025

6

Bearings Damage Cost

Bearing Damage in an year = 3 on an average
Bearing cost per piece MC (551350724800) = 158219
Bearing cost per year = Rs 158219 X 3
= Rs. 474657

7

Total Cost Saved

Total Assemblies planned per year = 76
Total Cost saved per year = Rs. 22025 X76
= RS. 16,73,900
Total Cost including damage cost saved = Rs.16,73,900+ 474657
= Rs. 21,48,557?

8

Hook Fabrication Cost

Material cost = Rs66 / kg X 1.3 kg
= Rs. 85.8
Cutting & Welding cost = Rs. 300/hour X 1 hour
= Rs. 300
Welding Consummable Cost = Rs. 2700 / kg X 0.1 kg
= Rs.270
Eye bolt cost = Rs. 850
Drilling tapping cost = Rs.300/ hour X 1 hour
= Rs.300
Total Hook Fabrication cost = Rs. 1805.8

9

Effective Cost Saved

= Rs. 21,48,557-1805.8
= Rs. 21,46,751.2
[0033] From the above, it can be observed that the proposed invention is cost effective.

[0034] 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.

[0035] 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.

[0036] 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”.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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 Bearing Assembly Device for Handling of Heavy Angular Bearing comprising of a clamp (1) connected to Eye bolt (2), wherein the clamp (1) is a single piece, which is having substantially U-section, in which the eye bolt (2) is fastened to the clamp (1).

2. The Bearing Assembly Device for Handling of Heavy Angular Bearing as claimed in claim 1, wherein the eye bolt (2) is fastened to the clamp (1) through a hole in the clamp (1).

3. The Bearing Assembly Device for Handling of Heavy Angular Bearing as claimed in claim 1 or 2, wherein clamp (2) has one leg (1A) longer than other leg (1B) in parallel to each other, in which the longer leg has the hole for assembly of the clamp with the eye bolt (2).

4. The Bearing Assembly Device for Handling of Heavy Angular Bearing as claimed in claims 1-3, wherein the legs (1A,1B) are perpendicular to the base (1C) of the clamp.

5. The Bearing Assembly Device for Handling of Heavy Angular Bearing as claimed in claims 1-4, wherein the eye bolt (2) is threadingly fastened in the threaded hole of the clamp (2) for tight grip.