Claims:1. A braking mechanism (100) for a carriage of a billet torch cutting machine (200), the mechanism (100) comprising:
a collar (101), rigidly coupled to a wheel shaft (102) extending from the carriage;
a disc (103), disposed on the wheel shaft (102) and rigidly coupled to the collar (101);
a brake caliper unit (104), straddled about the disc (103), and the brake caliper unit (104) configured to operatively engage the disc (103); and
an actuation unit (105), operatively coupled to the brake caliper unit (104), wherein the actuation unit (105) is configured to selectively operate the brake caliper unit (104) for engaging with the disc (103), to regulate movement of the wheel shaft (102) of the carriage.

2. The mechanism (100) as claimed in claim 1, wherein the wheel shaft (102) extends from an output shaft (106) of a motor (107).

3. The mechanism (100) as claimed in claim 1, comprises at least one locking member (108) to rigidly couple the disc (103) to the collar (101), wherein the disc (103) and the collar (101) are defined with at least one aperture (113, 115) for accommodating the at least one locking member (108).

4. The mechanism (100) as claimed in claim 1, wherein the disc (103) is made of mild steel.

5. The mechanism (100) as claimed in claim 1, wherein the actuation unit (105) is a pneumatic actuation unit.

6. The mechanism (100) as claimed in claim 1, comprises at least one sensor (109) configured to determine speed of the wheel shaft (102).

7. The mechanism (100) as claimed in claim 1, comprises an electronic control unit (ECU) (110) communicatively coupled to the at least one sensor (109), wherein the ECU (110) is configured to operate the actuation unit (105) for regulating movement of the carriage, based on input signals received from the at least one sensor (109) corresponding to speed of the wheel shaft (102).

8. The mechanism (100) as claimed in claim 1, wherein the brake caliper unit (104) comprises at least one brake pad (111) positioned on each side of the disc (103) and a piston for actuation of the at least one brake pad (111).

9. The mechanism (100) as claimed in claim 8, wherein the at least one brake pad (111) comprises brake lining on at least one surface that contacts the disc (103).

10. A billet torch cutting machine (200) comprising a braking mechanism (100) as claimed in claim 1.
, Description:TECHNICAL FIELD
The present disclosure, in general, relates to the field of metallurgy. Particularly, but not exclusively, the present disclosure relates to billet torch cutting machine. Further, embodiments of the present disclosure relate to a braking mechanism for a carriage of the billet torch cutting machine.

BACKGROUND OF THE DISCLOSURE
Steelmaking facilities employ metallurgical furnaces such as a blast furnace for produce liquid metal (also called as hot metal or liquid steel). Blast furnaces are configured to produce pig iron from iron ore, which is later processed into steel. During production, upon accumulation of a predetermined quantity of liquid metal and slag in hearth of the blast furnace, the liquid metal and slag are tapped through tapholes of the blast furnace, into torpedo ladles. The liquid metal is then subjected to process such as casting,

One such type of casting is a continuous casting process, which is followed in most steelmaking facilities. In the continuous casting process, liquid metal contained in the ladles is poured into a tundish for further processing. The tundish is a refractory lined open container and may have a refractory lined cover on the top. A bottom portion of the tundish may include one or more apertures equipped with slide gate(s) or stopper rod(s) for controlling flow of liquid metal. The apertures are adapted to feed liquid metal into moulds of a continuous casting machine, from which the liquid metal may be cast into billets, blooms, and slabs. A majority of billet casters (a type of continuous casting machine) are configured to cast billets with a length in range of 10 m to 12 m, at a casting speed of up to 4 m/minute.

In steelmaking facilities, automated gas cutting devices such as torch cutting machines are employed for cutting billets to desired length. The torch cutting machine engages with the billet to be cut and is configured to travel at a speed similar to that of the casting speed, to cut the billet to desired length. A conventional torch cutting machine includes two drive systems, namely, a carriage drive and a torch drive. The carriage drive is configured to provide motion to the torch cutting machine in a forward and a reverse direction across the width of the billet. The torch drive is configured to provide motion to a torch of the torch cutting machine, in a transverse direction (relative to the forward and reverse direction of the torch cutting machine). The carriage drive includes an actuation unit, such as an electric motor, for providing motion to the torch cutting machine. A drive shaft of the electric motor may be operatively coupled to wheels of the torch cutting machine through a gearbox. The electric motor may further include an electrical brake unit, such as an electromechanical brake, configured to decelerate/brake the electrical motor, and thereby control motion of the torch cutting machine. With the above-described configuration, the torch cutting machine may be held in its position by actuation of the electrical brake unit.

Due to an elevated temperature environment surrounding the torch cutting machine, the electromechanical brake is subjected to temperatures in the range of 300 ? to 350 ? and beyond. Further, the electromechanical brake is exposed to hot splinters and burrs that are emitted during cutting of billets. Such operational environment leads to frequent failure of electromechanical brakes of the torch cutting machine, resulting in an increased operational downtime of the torch cutting machine. Moreover, such frequent and unexpected failure of the electromechanical brakes results in stoppage of billet cutting and/or inaccurate cutting of billets. Also, with the advancements in the manufacturing, size of the billets casted from the continuous casters are increasing day by day. Such increase in size of the billets put additional load on the carriage unit, and thus on the electromechanical brakes, thereby leading to frequent failures.

The present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the conventional type of torch cutting machine employed in cutting of billets.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the conventional type of torch cutting machine employed in cutting of billets are overcome by a braking mechanism as claimed and additional advantages are provided through the braking mechanism as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the present disclosure, a braking mechanism for a carriage of a billet torch cutting machine is disclosed. The mechanism includes a collar that is rigidly coupled to a wheel shaft extending from the carriage. A disc is disposed on the wheel shaft and is rigidly coupled to the collar. Further, the mechanism includes a brake caliper unit which is straddled about the disc. The brake caliper unit is configured to operatively engage the disc. The mechanism further includes an actuation unit that is operatively coupled to the brake caliper unit. The actuation unit is configured to selectively operate the brake caliper unit for engaging with the disc, to regulate movement of the wheel shaft of the carriage.

In an embodiment of the present disclosure, the wheel shaft extends from an output shaft of a motor.

In an embodiment of the present disclosure, the braking mechanism includes at least one locking member to rigidly couple the disc to the collar. The disc and the collar are defined with at least one aperture for accommodating the at least one locking member.

In an embodiment of the present disclosure, the disc is made of mild steel.

In an embodiment of the present disclosure, the actuation unit is a pneumatic actuation unit.

In an embodiment of the present disclosure, the mechanism includes at least one sensor configured to determine speed of the wheel shaft.

In an embodiment of the present disclosure, the mechanism includes an electronic control unit (ECU) communicatively coupled to the at least one sensor. The ECU is configured to operate the actuation unit for regulating movement of the carriage. Movement of the carriage may be regulated based on input signals received from the at least one sensor corresponding to speed of the wheel shaft.

In an embodiment of the present disclosure, the caliper unit includes at least one brake pad positioned on each side of the disc and a piston for actuation of the at least one brake pad.

In an embodiment of the present disclosure, the at least one brake pad comprises brake lining on at least one surface that contacts the disc.

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

The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

Figure 1 illustrates a schematic view of a billet torch cutting machine including a braking mechanism, in accordance with an exemplary embodiment of the present disclosure.

Figure 2 illustrates the braking mechanism employed in a billet torch cutting machine, in accordance with the exemplary embodiment of the present disclosure.

Figure 3 illustrates a collar included in the braking mechanism of Figure 2.

Figure 4 illustrates a disc included in the braking mechanism of Figure 2.

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 system and the method illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

While the embodiments in the disclosure are subject to various modifications and alternative forms, specific embodiments thereof have been shown by the 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.

The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover non-exclusive inclusions, such that a device, assembly, mechanism, system, method 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 proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.

Embodiments of the present disclosure disclose a braking mechanism for a carriage of a billet torch cutting machine. The mechanism includes a collar that is rigidly coupled to a wheel shaft extending from the carriage. A disc is disposed on the wheel shaft and is rigidly coupled to the collar. Further, a brake caliper unit is straddled about the disc and is configured to operatively engage with the disc. The mechanism further includes an actuation unit operatively coupled to the brake caliper unit. The actuation unit is configured to selectively operate the brake caliper unit for engaging with the disc, to regulate movement of the wheel shaft of the carriage.

The term ‘billet’ as used herein refers to a solid semi-finished rectangular, square, or round product of steel that has been produced by continuous casting. The term ‘carriage’ of the billet torch cutting machine, as used herein refers to an enclosure or housing within which the components of the billet torch cutting machine are accommodated, and the carriage is configured to displaced along a forward and a reverse direction along a guideway.

The disclosure is described in the following paragraphs with reference to Figures 1 to 4. In the figures, the same element or elements which have same functions are indicated by the same reference signs. It is to be noted that, the entire continuous casting machine associated with the blast furnace and the billet torch cutting machine in its entirety, are not illustrated in the figures for the purpose of simplicity. One skilled in the art would appreciate that the mechanism as disclosed in the present disclosure may be used in any torch cutting machine including, but not limited to, gas cutting machines and portable cutting machines that require movement control.

Figure 1 is an exemplary embodiment of the present disclosure illustrating a schematic view of a billet torch cutting machine (200) (simply referred to as ‘machine’ hereafter) including a braking mechanism (100) (simply referred to as ‘mechanism’ hereafter) for a carriage of the billet torch cutting machine (200). Further, Figure 2 illustrates the braking mechanism (100) employed in the billet torch cutting machine (200), in accordance with the exemplary embodiment of the present disclosure. The braking mechanism (100) may include a collar (101) rigidly coupled to a wheel shaft (102). The wheel shaft (102) may be extending from the carriage of the machine (200). Further, a disc (103) may be disposed on the wheel shaft (102) and may be rigidly coupled to the collar (101). A brake caliper unit (104) may be straddled about the disc (103), and the brake caliper unit (104) may be configured to operatively engage with the disc (103). The mechanism (100) may further include an actuation unit (105). The actuation unit (105) may be operatively coupled to the brake caliper unit (104). In an embodiment, the actuation unit (105) may be a pneumatic actuation unit. The actuation unit (105) may be configured to selectively operate the brake caliper unit (104) for engaging with the disc (103), to regulate movement of the wheel shaft (102) of the carriage.

Figure 3 illustrates the collar (101) of the mechanism (100). The collar (101) may be a ring-shaped article configured to be rigidly coupled to the wheel shaft (102). The collar (101) may be made of a rigid material, such as, but not limited to, mild steel. An internal diameter (112) of the collar (101) may be substantially equal to an external diameter of the wheel shaft (102). In an exemplary embodiment, the internal diameter (112) of the collar (101) may be 61 mm, which is substantially equal to the external diameter of the wheel shaft (102). The collar (101) may be rigidly coupled to the wheel shaft (102), such that there is no relative movement between the collar (101) and the wheel shaft (102). The collar (101) may include a plurality of first apertures (113) defined in a circular arrangement, relative to a central axis (A-A) of the collar (101). In an embodiment, the collar (101) may have nine number of first apertures (113) and the first apertures (113) may have a radial angle of 40 degrees therebetween. The plurality of first apertures (113) may have a diameter of 8.5mm. The plurality of first apertures (113) may be threaded apertures and may be defined with internal threads. Each of the plurality of first apertures (113) may be configured to accommodate at least one locking member (108). The at least one locking member (108) may be defined with external threads that may complement profile of the internal threads in the plurality of first apertures (113) defined in the collar (101). The external threads of the at least one locking member (108) may meshingly engage with the internal threads of the plurality of first apertures (113).

The wheel shaft (102) may be a solid cylindrical rod extending from an output shaft (106) of a motor (107) of the machine (200). Upon actuation of the motor (107), the output shaft (106) may be configured to drive the wheel shaft (102). The wheel shaft (102), as the name suggests, may be coupled to at least one wheel (not shown in the figure) of the carriage. The wheel shaft (102) may be coupled to at least one wheel of the carriage through a gearbox of the mechanism (100). Speed of the at least one wheel, and thereby that of the carriage, may be controlled by the gearbox of the mechanism (100).

Further, Figure 4 illustrates a front view and a sectional view (taken along section A-A, as depicted in the front view) of the disc (103) of the mechanism (100). The disc (103) may made of rigid material, such as, but not limited to, mild steel. The disc (103) may include a central opening (114) defined coaxially with respect to a central axis (C-C) of the disc (103). In an exemplary embodiment, the disc (103) may have a diameter (116) of 185 mm and may have a thickness (118) of 14 mm. Diameter (117) of the central opening (114) may be substantially equal to an external diameter of the wheel shaft (102). In an embodiment, the diameter (117) of the central opening (114) may be 61 mm, which is substantially equal to the external diameter of the wheel shaft (102). The disc (103) may be coupled to the wheel shaft (102) with at least one of a transition fit and an interference fit therebetween, such that there is no relative movement between the disc (103) and the wheel shaft (102). The disc (103) may include a plurality of second apertures (115) defined in a circular arrangement relative to the central opening (114). In an embodiment, the disc (103) may have nine number of second apertures (115) and the plurality of second apertures (115) may have a radial angle of 40 degrees therebetween. The plurality of second apertures (115) may have a diameter of 8.5mm. The plurality of second apertures (115) may be threaded apertures and may be defined with internal threads. Each of the plurality of second apertures (115) may be configured to accommodate the at least one locking member (108). The at least one locking member (108) may be defined with external threads that may complement profile of the internal threads in the plurality of second apertures (115) defined in the disc (103). The external threads of the at least one locking member (108) may meshingly engage with the internal threads of the plurality of second apertures (115).

In an embodiment, the at least one locking member (108) may be a fastener configured to rigidly couple the disc (103) to the collar (101). The at least one locking member (108) may be at least one of a screw, pin, nut and bolt (may include a washer), stud and the like.

Referring to Figure 2 again, the collar (101) and the disc (103) are mounted on the wheel shaft (102). The collar (101) is rigidly coupled to the disc (103) such that, the plurality of first apertures (113) of the collar (101) are aligned coaxially with the plurality of second apertures (115) of the disc (103). The external threads of the at least one locking member (108) meshingly engages with the internal threads of the plurality of first apertures (113) and the plurality of second apertures (115). Such meshing engagement between the at least one locking member (108) and the collar (101), the disc (103), ensures that there is no relative movement therebetween, and positively locks the collar (101) with the disc (103).

The brake caliper unit (104) may be straddled about the disc (103) and may be configured to operatively engage with the disc (103). The brake caliper unit (104) includes at least one brake pad (111) positioned on each side of the disc (103). As depicted in the Figure 2, the at least one brake pad (111) may be disposed on either side of the disc (103) by means of a connecting arm (119). The at least one brake pad (111) may be provided with brake lining on at least one surface that contacts the disc (103). The brake caliper unit (104) may further include a piston (not show in the figure) for actuation of the at least one brake pad (111). The piston of the brake caliper unit (104) may be actuated by the actuation unit (105). In an embodiment, the actuation unit (105) may be a pneumatic actuation unit. Upon actuation of the piston by the actuation unit (105), the piston displaces the at least one brake pad (111) towards the disc (103). In such displaced condition, the at least one brake pad (111) (particularly, the brake lining) slidably engages with surface of the disc (103). Such slidable engagement between the at least one brake pad (111) and the disc (103), decelerates and brakes the rotational motion of the disc (103). By controlling the rotational motion of the disc (103) as described above, the movement of the wheel shaft (102) of the carriage may be regulated.

As illustrated in Figure 2, the mechanism (100) may include at least one sensor (109) configured to determine speed of the wheel shaft (102). The at least one sensor (109) may be suitably interfaced with the wheel shaft (102) such that, the speed of the wheel shaft (102) may be determined without any lag/errors. Further, the at least one sensor (109) may be configured to determine at least one a speed, velocity, acceleration, deceleration, and revolutions per minute (RPM) of the wheel shaft (102). The at least one sensor (109) may be an inductive sensor (monopolar or bipolar) or an active sensor, such as, but not limited to, a magneto-resistive sensor and a Hall effect sensor. However, the at least one sensor (109) may be at least one of an AC-response accelerometer and a DC-response accelerometer.

The mechanism (100) may further include an electronic control unit (ECU) (110) communicatively coupled to the at least one sensor (109). The ECU (110) may also be operatively coupled to the actuation unit (105) and to the motor (107). The ECU (110) may be configured to operate the actuation unit (105) for regulating movement of the carriage. The ECU (110) regulates the movement of the carriage, based on input signals received from the at least one sensor (109), corresponding to the speed of the wheel shaft (102).

In an embodiment of the disclosure, the electronic control unit (ECU) (110) may be a centralized control unit, or a dedicated control unit associated with the braking mechanism (100). The ECU (110) may be implemented by any computing systems that is utilized to implement the features of the present disclosure. The ECU (110) may be comprised of a processing unit. The processing unit may comprise at least one data processor for executing program components for executing user- or system-generated requests. The processing unit may be a specialized processing unit such as integrated system (bus) controllers, memory management control units, floating point units, graphics processing units, digital signal processing units, etc. The processing unit may include a microprocessor, such as AMD Athlon, Duron or Opteron, ARM’s application, embedded or secure processors, IBM PowerPC, Intel’s Core, Itanium, Xeon, Celeron, or other line of processors, etc. The processing unit may be implemented using a mainframe, distributed processor, multi-core, parallel, grid, or other architectures. Some embodiments may utilize embedded technologies like application-specific integrated circuits (ASICs), digital signal processors (DSPs), Field Programmable Gate Arrays (FPGAs), and the like.

Further, in some embodiments, the processing unit may be disposed in communication with one or more memory devices (e.g., RAM, ROM etc.) via a storage interface. The storage interface may connect to memory devices including, without limitation, memory drives, removable disc drives, etc., employing connection protocols such as serial advanced technology attachment (SATA), integrated drive electronics (IDE), IEEE-1394, universal serial bus (USB), fiber channel, small computing system interface (SCSI), etc. The memory drives may further include a drum, magnetic disc drive, magneto-optical drive, optical drive, redundant array of independent discs (RAID), solid-state memory devices, solid-state drives, and the like.

In an embodiment, the braking mechanism (100) provides a movement control apparatus for a carriage of a billet torch cutting machine (200), that is compact and simple in construction in comparison with the electromechanical brake of the conventional type of torch cutting machine. The mechanism (100) includes fewer moving parts and hence, has reduced wear and tear and higher service life, in comparison with braking unit of the conventional type of torch cutting machine. The configuration of the braking mechanism (100) allows easy access to the brake caliper unit (104) and facilitates easy replacement and maintenance of the at least one brake pad (111). The mechanism (100) offers better movement control of the carriage and has reduced operational downtime, in comparison with the electromechanical brake of the conventional type of torch cutting machine. Thus, instances of stoppage of billet cutting and/or inaccurate cutting of billets are substantially reduced. The configuration of the mechanism (100) ensures that the mechanism (100) does not suffer from frequent and unexpected failures, when operated in elevated temperature environments, while being exposed to hot splinters and burrs that are emitted during cutting of billets.

EQUIVALENTS

With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

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 particular 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 analogous 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 (100) 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 (100) 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.”

In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

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.

REFERRAL NUMERICALS
Particulars Numerical
Braking mechanism 100
Collar 101
Wheel shaft 102
Disc 103
Brake caliper unit 104
Actuation unit 105
Output shaft 106
Motor 107
Locking member 108
Sensor 109
ECU 110
Brake pad 111
Internal diameter of the collar 112
First apertures 113
Central opening 114
Second apertures 115
Diameter of the disc 116
Diameter of central opening 117
Thickness of the disc 118
Connecting arm 119
Billet torch cutting machine 200