Description:
TECHNICAL FIELD
[0001] The present subject matter described herein, relates to a device and method for making large diameter holes in tapered heavy thickness plate. More particularly, the present invention relates to reduce operator fatigue and ensure safe work condition while setting and gas cutting of tapered heavy thickness plates, the same can be used to the process of setting and gas cutting on various shape of heavy plates for different length and width.
BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. Tapered heavy thickness plates (11) are used in structural part in power plant house building. power plants are the large cooling towers and the boiler frame structures, which, however, are later enclosed by the boiler house. But not only these large structures make up a power plant. A number of dependent buildings are necessary to accommodate all the necessary units, such as the power house, heavy plate technology for steelwork are characterized by the user’s desire to facilitate further reductions of fabrication costs using further improved heavy plates.
[0003] This structural heavy plate has various size and shape based on design and drawing requirements. It is used to carry the heavy load according to the need of various area.
[0004] The tapered heavy thickness plates need number of process. First select the suitable raw material. The plates are seen shear UT for the laminations and tears in the plate. If the UT is alright the layout marking is done. After the layout marking the plates are inspected and are gas cut.
[0005] The plates after gas cutting are loaded in the 150T furnace and the plates are heated. The temperature at which the plates to be heated is 880-900 deg C. The time up to which the soaking temperature is to be maintained is called the soaking time. The soaking time is normally 1.25 times the maximum thickness of the plate. After the soaking is maintained the plates are taken out from the furnace and are pressed in the 8000T press.
[0006] Generally, the required shape of die is setting on 8000TON pressing machine After the plates are loading on pressing machine and hot formed into require shape of tapered heavy thickness plates, after pressing completed the heavy plates are subjected into quenching process. The plate after heat treatment process marking and punching need for gas cutting purpose.
[0007] For proper level setting purpose to search and collect require fabricated iron block (12) and wooden pieces (13). then job loading on iron block (12) and wooden pieces (13) by using crane (14) (fig-2), so crane engagement more while setting, manual hammering (16) also need for job level adjustment and levelling take more time and skilled and experience person is needed, where sprit level (15) is used for level checking purpose. While level adjusting some time fabricated iron block (12) and wooden piece (13) is disturbed. it is very unsafe condition to the operator because heavy thickness plate having weight is 600 kg. (approx.)
[0008] After level setting user use manual gas cutting holder (17) for to make diameter 250 mm hole. Gas cutting surface is very poor and profile also not in uniform because of manual gas cutting method (fig-4a).
[0009] To make a proper profile and to get require surface rework grinding is done for the diameter 250 mm hole surface area, Here the plate subjected to heat treatment process, so hardness of material is more, so grinding take more time and difficult to maintain the require dimension.
[0010] Here level setting (fig-3), manual gas cutting (17) and grinding take more cycle time and can cause operator fatigue. which tend to decrease the productivity of the manufacture of the heavy plate.
[0011] Where the problem is level setting and gas cutting after the tapered heavy thickness plate hot forming and marking completed. The existing method is not a fixed procedure for the heavy plate level setting and gas cutting.
[0012] Therefore, there is a need for a device and method for making large diameter holes in tapered heavy thickness plate.

OBJECTS OF THE DISCLOSURE
[0013] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0014] The principal object of the present subject matter is to propose reduce operator fatigue while job locating on rigid position.
[0015] Another object of the present subject matter is to propose human activities like hammering and pushing the job by hand reduced (ergonomics) while Job level setting.
[0016] Another object of the present subject matter is to propose to reduce crane engagement time while setting and material handling process,
[0017] Another object of the present subject matter is to propose to eliminate the rework grinding process on gas cutting hole.
[0018] Another object of the present subject matter is to propose to reduce cycle time for level setting and gas cutting process.
[0019] Another object of the present subject matter is to proposed to increase the productivity of heavy plates.
[0020] These and other objects and advantages will become more apparent when reference is made to the following description and accompanying drawings.
SUMMARY
[0021] This summary is provided to introduce concepts related to a device and method used for making large diameter holes in tapered heavy thickness plate.
[0022] The device simplifies the unsafe material handling process in setting and gas cutting process of tapered heavy thickness plates having weight 600 kg per piece.
[0023] The fabricated load carrying beam is welded on base plate. A load carrying beam have two threaded holes used for attaching two numbers of level adjusting screw, back support channels are welded between base plate and load carrying beam, the back support channels are used to support load carrying beam while carrying full load.
[0024] A bottom locater is welded on base plate using for carrying weight of the bottom side of the tapered heavy thickness plate.
[0025] A center line locater block is welded on base plate with front support channel, the center line locater block has center line mark it used to guide the tapered heavy thickness plate to locate exact center.
[0026] A fabricate 4 numbers of screw jack for using carry the auto gas cutting machine while gas cutting on heavy plate.
[0027] A bottom of base plate is provided with numbers of bottom block for fixture movement and locating purpose.
[0028] The assembly of device is used to reduce the operator fatigue while setting and gas cutting of tapered heavy thickness plates and this auto gas cutting method (fig-9) improve the gas cutting surface quality and eliminate the rework grinding process.
[0029] 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 DRAWINGS
[0030] The illustrated embodiments of the subject matter will be understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
[0031] Fig. 1 shows the tapered heavy thickness plate, in accordance with an embodiment of the present subject matter;
[0032] Fig. 2a and Fig. 2b shows the tapered plat loading and setting process on iron blocks in old method, in accordance with an embodiment of the present subject matter;
[0033] Fig. 3a and Fig. 3b shows the old method of level setting process by manual hammering, in accordance with an embodiment of the present subject matter;
[0034] Fig. 4a and Fig. 4b shows the old method of manual gas cutting process to make a require hole on tapered heavy thickness plate, in accordance with an embodiment of the present subject matter;
[0035] Fig. 5 shows the part drawing of new device with 7 items, in accordance with an embodiment of the present subject matter;
[0036] Fig. 6 shows the part drawing of new device with 2 items, in accordance with an embodiment of the present subject matter;
[0037] Fig. 7 shows the assemble drawing of new device, in accordance with an embodiment of the present subject matter;
[0038] Fig. 8 shows the tapered heavy thickness plate locating and level setting process on new device, in accordance with an embodiment of the present subject matter;
[0039] Fig. 9 shows the hole making process on tapered heavy thickness plate auto gas cutting method using new device, in accordance with an embodiment of the present subject matter; and
[0040] Fig. 10 shows a flow diagram of a method used for setting and making large diameter holes in a tapered heavy thickness plate, in accordance with an embodiment of the present subject matter.
[0041] 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
[0042] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the scope of the present disclosure as defined by the appended claims.
[0043] 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 present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0044] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a",” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0045] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0046] In addition, the descriptions of "first", "second", “third”, and the like in the present invention are used for the purpose of description only, and are not to be construed as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Thus, features defining "first" and "second" may include at least one of the features, either explicitly or implicitly.
[0047] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0048] Fig. 7 shows the assemble drawing of a new device according to some example embodiment of the invention. In an embodiment, a device (18) consist of a base plate (1) welded with a load carrying beam (3) and a back support channel (5). Another side of the base plate (1) welded with a center line locater block (6) and a front support channel (7). The bottom locater block (2) is welded on base plate for job location purpose. A two numbers of a level adjusting screw (4) provided on the load carrying beam (3) top end for job level setting purpose. The two numbers of a bottom block (10) welded at the bottom of the base plate (1) for fixture handling purpose. A fabricated 4 numbers of a screw jack (8) is used for carrying and locating of an auto gas cutting machine (9) while making large diameter holes.
[0049] The device (18) is moved on gas cutting area. A tapered heavy thickness plate (11) loaded on a fixture (18) by using a crane (14), job properly located at center of the device by using the center line locater block (6), after loading crane (14) is released for another work. so here, user reduce crane (14) engagement while job setting process (fig-2b, 3a, 3b & 4a), the tapered plate (11) one end located on the bottom locater (2) and another end located on the level adjusting screw (4). The center line locater (6) prevents to slippage of tapered heavy plates (11).
[0050] The plate level is checked using a sprit level (15), to set the proper level user adjust the level adjusting screw based on the sprit level (15) indication. Using level adjusting screw user easily adjust the heavy plate in require level (fig-8), so here user eliminate the manually pushing the plate and a hammering process (16) while level setting.
[0051] After level setting completed auto gas cutting (9) machine are locate on require position on heavy plate using screw jacks (fig-9). Then connect the gas line and gas cutting is start in require hole size. Auto gas cutting make good surface finish and require whole size, so rework grinding process is eliminated.
[0052] After making a require hole gas cutting machine re located and heavy plate unloaded from new device.
[0053] The advantages of using the device (18) is that human activities are reduced (ergonomics) while job level setting process (fig-2b & 3b) because using the device (18) the manual human material handling (fig-2b) and hammering (fig-3b) is eliminated the operator fatigue is reducing while level process,
[0054] The device (18) is used to make various diameter hole on various shape of tapered heavy plates (11). In the auto gas cutting method (fig-9) hole surface finish is highly improved and user got require shape and size of the hole, hence rework grinding process is eliminated.
[0055] The device (18) total cycle time is reduced and productivity is increased.
[0056] Fig. 10 shows a flow diagram of a method for setting and making large diameter holes in a tapered heavy thickness plate, the method comprising:
[0057] Loading the tapered heavy plate on the device (18) with proper center using the center line locater block (6).
[0058] Setting the tapered heavy plate on required level using level adjusting screw.
[0059] Setting the auto gas cutting machine (9) on the tapered heavy plate (11) with the help of screw jacks for making large diameter of hole through auto gas cutting process.
[0060] 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 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.”
[0061] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

Claims:
We claim:
1. A device (18) for setting and machining of boiler fittings while edge preparation machining on center lathe, the device (18) comprising:
- a base plate (1);
- a bottom locater (2) welded on the base plate (1) using for carrying weight of the bottom side of the plate;
- a load carrying block (3) welded on the base plate (1), the load carrying block (3) having at least two threaded hole used for attaching two numbers of a level adjusting screw (4);
- a back support channels (5) are welded between the base plate (1) and the load carrying block (3);
- a center line locater (6) welded on the base plate (1) with a front support channel (7);
- a front support channel (7) is used to support the center line locater (6) while job locating;
- a four numbers of a screw jack (8) used for carry an auto gas cutting machine (9) while gas cutting on the heavy plate; and
- a two numbers of a bottom block (10) used for a fixture movement and a locating purpose.

2. The device (18) as claimed in claim 1, wherein the two numbers level adjusting screw (4) using to set the plate level adjustment while level setting process.

3. The device (18) as claimed in claim 1, wherein the back support channels (5) is used to support the load carrying block (3) while carrying full load.

4. The device (18) as claimed in claim 1, wherein the center line locater (6) having a center line mark which is used to guide the heavy plate to locate the exact center.

5. A method (30) for setting and making large diameter holes in a tapered heavy thickness plate, the method comprising:
- loading the tapered heavy plate on the device (18) with proper center using the center line locater block (6);
- setting the tapered heavy plate on required level using level adjusting screw; and
- setting the auto gas cutting machine (9) on the tapered heavy plate (11) with the help of screw jacks for making large diameter of hole through auto gas cutting process.