Description:FIELD OF THE INVENTION:
[001] The present invention, in general, relates to a fixture and methodology used for manufacturing a nozzle that is used in the separator vessel of a boiler to remove the moisture content from the steam generated. More particularly, the present invention relates to the structure of the fixture used to hold the raw material pipe in Double Column Band Saw Machine with 600 indexing position and also 50 inclined position in-order to get the nozzle with minimum profile machining required.
BACKGROUND OF THE INVENTION:
[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] In boiler applications, Once-Through Super-Critical Boiler is a type of boiler that works at high temperatures & high pressure which cannot be achieved instantaneously. Therefore, the start-up system is provided that changes the mode of the boiler from sub-critical mode to super-critical mode. The start-up system consists of a separator vessel.

[004] The separator vessel is considered as the main part of the start-up system which replaces few functions of a boiler drum when the boiler is in a sub-critical mode. The main function of the separator vessel is to separate moisture from the steam through vortex generation. The vortex generation is achieved by tilting a plurality of nozzles 50 towards the top side of the separator vessel and offsetting the nozzles axis with respect to a pipe axis (on which it is welded). This axis offset and tilted angle of the nozzle makes the nozzle edge preparation complex.

[005] Moreover, the nozzle edge preparation is done by profile machining. This profile machining decides the fit-up condition, such as root-gap and orientation of the nozzle. A small variation in the profile machining can severely affect the performance of the boiler, as the orientation of the nozzle decides the vortex generation. To avoid these adverse effects, the error in the profile machining is compensated through root gap adjustments, which in turn makes welding difficult. The cycle time of this vital profile machining operation is very high as the raw material stock removal is more. This unnecessary stock removal accounts for material wastage and poor resource utilization.

[006] Furthermore, the plurality of nozzles of the Separator Vessel is machined from a pipe having length ranges between 550 mm to 600 mm as per the drawing requirement. This pipe is initially step turned on one side and then bored in SKS 25 Vertical Boring Machine. Then the resultant step turned and the bored pipe is moved for profile machining to CNC Toskurim Plano Milling Machine to produce the nozzle of required dimension. The cycle time for profile machining of the resultant pipe is too high because of high stock removal.

[007] Therefore, there is a need to provide a fixture and a method that reduces the cycle time of nozzle profile machining but also reducing the raw material consumption.
OBJECTS OF THE INVENTION:
[008] It is, therefore, the object of the present invention is to overcome the aforementioned and other drawbacks existing in prior systems.

[009] Another object of the present invention is to develop a fixture for holding a raw material pipe at a double column band saw the machine which cut the raw material pipe into two pieces with the required angle.

[0010] Another object of the present invention is to develop the fixture which facilitates the user to set the raw material pipe in 50 angles (nozzle inclination towards the top side of the Separator Vessel). The nozzle with the fixture is then set on the machine table to 600 indexing angle which ensures optimal stock removal and full material utilization.

[0011] Yet another object of the present invention is to use the raw material pipe of 1000 mm length to get two nozzles.

[0012] Yet another object of the present invention is to develop the method that results in minimal stock removal.

[0013] Yet another object of the present invention is to develop the method that reduces the cycle time of the nozzle profile machining.

[0014] 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.
SUMMARY OF THE INVENTION:
[0015] To attain the above objects, the present invention provides a nozzle raw material pipe of 1000 mm length. The raw material pipe is step turned on both sides and bored in SKS 25 Vertical Boring Machine. The present invention also corresponds to the design & development of a new fixture to hold the step turned and bored raw material pipe with 50 incline positions (having 1000 mm length) and the fixture with raw material pipe is positioned in Double Column Band Saw Machine with 600 indexing position which cuts the raw material pipe into two pieces with required angle. In an aspect, the step turned nozzle raw material pipe is placed in the new fixture and clamped using 4 sets of clamping screws.

[0016] In an aspect, the new fixture includes a bottom plate that supports the nozzle raw material pipe includes a plurality of “V” blocks that are fitted to the bottom plate either through a welding means or fastening means.

[0017] In an aspect, the plurality of V-blocks includes two fixed and two adjustable “V” blocks.

[0018] In an aspect, the fixed “V” blocks attached to the bottom plate through the welding means and the adjustable “V” blocks attached to the bottom plate through the fastening means that includes a plurality of studs, a plurality of locknuts and a plurality of guide tubes.

[0019] In an aspect, the plurality of V-blocks of different height is placed over the bottom plate in descending order to ensure a 5-degree inclination of the raw material pipe with the bottom plate.

[0020] In an aspect the step turned raw material pipe is clamped with the plurality of “V” blocks by utilizing a plurality of studs, a plurality of nuts and a V clamp.

[0021] In an aspect, the stopper plate is also provided in a fixture to stop the pipe from sliding down due to gravitational force after the cutting is completed.

[0022] In an aspect, the new fixture with the step-turned pipe is then placed on the machine table (Double Column Band Saw Machine) with an indexing angle of 600. The step turned pipe is then cut into two pieces with 600 indexing angle. The cut pipes are then moved to CNC Toskurim Plano Milling Machine for final profile machining. This method has resulted in minimal stock on the profile machining face which has reduced the cycle time and minimized raw material wastage.

[0023] 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.

[0024] 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 the following detailed description.

[0025] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWING:
[0026] 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:
[0027] Figure 1 illustrates a Separator Vessel along with a plurality of nozzles, according to an embodiment of the present invention;

[0028] Figure 2 illustrates a section AA (cross-section of separator vessel with a plurality of nozzles showing the offset), according to an embodiment of the present invention;
[0029] Figure 3 illustrates a profile machined nozzle, according to an embodiment of the present invention;

[0030] Figure 4 illustrates a bottom plate of a fixture, according to an embodiment of the present invention;

[0031] Figure 5 illustrates a “V” block which is welded on the bottom plate, according to an embodiment of the present invention;

[0032] Figure 6 illustrates another “V” block which is welded on the bottom plate, according to an embodiment of the present invention;

[0033] Figure 7 illustrates an adjustable “V” block which is fastened on the bottom plate, according to an embodiment of the present invention;

[0034] Figure 8 illustrates another adjustable “V” block which is fastened on the bottom plate, according to an embodiment of the present invention;

[0035] Figure 9 illustrates a stud and a nut to hold a raw material pipe with “V” block, according to an embodiment of the present invention;

[0036] Figure 10 illustrates an orthographic view of the assembled fixture, according to an embodiment of the present invention;

[0037] Figure 11 illustrates a raw material pipe cutting operation in Double Column Band Saw Machine, according to an embodiment of the present invention; and

[0038] Figure 12 illustrates two pieces of a raw material pipe after cutting operation in Double Column Band Saw Machine, according to an embodiment of the present invention;

[0039] 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 an exemplary a fixture & methodology used for separator nozzle profile machining, according to an embodiment of the present invention structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION:
[0040] While the embodiments of the disclosure are subject to various modifications and alternative forms, a specific embodiment thereof has 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 alternatives falling within the scope of the disclosure.
[0041] 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.
[0042] 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 the 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, apparatus or device. Hereinafter a dual-mode sequential lamp for automotive vehicles is explained in detail
[0043] Referring to Figure 1, illustrating a separator Vessel (01) along with a plurality of nozzles (02), according to an embodiment of the present invention is considered as the main part of start-up system in a super-critical boiler. The separator vessel includes 6 nozzles (02). The function of the nozzles is to separate the moisture from the steam generated in the super-critical boiler through vortex generation. The vortex generation is achieved by tilting the plurality of nozzles 50 towards the top side of the separator vessel (01) and offsetting the nozzles axis and the pipe (on which it is welded) axis.

[0044] Referring to Figure 2, illustrating a section AA (cross-section of separator vessel with a plurality of nozzles showing the offset), according to an embodiment of the present invention. The vortex generation inside the separator vessel (01) that is used to separate the moisture from the steam generated in the boiler is achieved by tilting the plurality of nozzles 50 towards the top side of the separator vessel (01) and offsetting the nozzles axis and the pipe (on which it is welded) axis.

[0045] Referring to Figure 3, illustrating the profile machined nozzle (02), according to an embodiment of the present invention, the step turned raw material pipe (18) having 1000 mm length is fixed with the Double Column Band Saw machine at an angle of 600; and cutting the said step turned raw material pipe (18) having 1000 mm length into two pieces of equal length. The resultant two pieces are profile machined (03) to form a two profile machined nozzle (02).

[0046] Referring to Figure 4, illustrating a bottom plate (04) of a fixture (16), according to an embodiment of the present invention, the bottom plate (04) of the fixture is used to mount the plurality of V- blocks either through the welding means or fastening means.

[0047] Referring to Figure 5, illustrating a “V” block (05) which is welded on the bottom plate. The “V” block (05) is also called a fixed block as it is welded to the bottom plate (04) of the fixture (16).

[0048] Referring to Figure 6, illustrating another “V” block (06) which is welded on the bottom plate (04), according to an embodiment of the present invention. The “V” block (06) is also welded to the bottom plate (04) of the fixture (16) through the welding means.

[0049] Referring to Figure 7, illustrating an “adjustable V” block (07) which is fastened to the bottom plate (04), according to an embodiment of the present invention. The “V” block (07) is fastened to the bottom plate (04) of the fixture (16) through the fastening means such as studs (8a), locknut (9a) and guide tube (10a).

[0050] Referring to Figure 8, illustrating another “adjustable V” block which is fastened to the bottom plate (04), according to an embodiment of the present invention. The “V” block (11) is fastened to the bottom plate (04) of the fixture (16) through the fastening means such as studs (8b), locknut (9b) and guide tube (10b).

[0051] Referring to Figure 9, illustrating a stud and a nut to hold the raw material pipe with “V” block, according to an embodiment of the present invention. The stud (13) and the nut (12) are provided to hold a raw material pipe with the plurality of V-blocks (05,06,07,11).

[0052] Referring to Figure 10, illustrating the orthographic view of the assembled fixture, according to an embodiment of the present invention. The fixture includes a plurality of V-blocks (05,06,07,11), a bottom plate (04) and a stopper plate (14). A plurality of V-blocks (05,06,07,11) includes two fixed V-blocks (05,06) and two adjustable V-blocks (07,11). The fixed V-blocks (05,06) are attached to the bottom plate (04) through the welding means. The adjustable V-blocks (07,11) are attached to the bottom plate (04) through the fastening means such as studs (8a, 8b), nuts (9a,9b) and guide tube (10a,10b). The V- blocks hold the raw material pipe through the plurality of studs (13a,13b,13c,13d), the plurality of nuts (12a,12b,12c,12d) and a V-clamp (15). The stopper plate (14) is also provided to stop the raw material pipe (18) from sliding down due to gravitational force.

[0053] Referring to figure 11, illustrating the raw material pipe cutting operation in Double Column Band Saw Machine, according to an embodiment of the present invention. The raw material pipe is inclined to 50 by resting it on four “V” blocks (05), (06), (07) and (11). Then the raw material pipe is clamped with these “V” blocks by using four sets of studs (13), nuts (12) and “V” clamps (15). Then the fixture with nozzle raw material pipe is placed on the Double Column Band Saw Machine with an indexing angle of 600.

[0054] Referring to figure 12, illustrating two pieces of nozzle pipes after cutting operation in Double Column Band Saw Machine, according to an embodiment of the present invention. After the Band Saw Cutting operation, the nozzle raw material pipe is cut into two pieces from 1000 mm length pipe and also gets the cutting face is a replica to the profile machined face. By this process, the face to be profile machined (03) gets minimal stock. This innovative process is able to give minimal stock during profile machining because of the indexing angle 600 on the Band Saw Cutting Machine and the inclination angle 50 provided by the fixture. Moreover, the minimal stock is also attributed to a smaller raw material length.

Claims:1. A fixture (16) for securing a raw material pipe (18) to be machined in a Double Column Band Saw Machine, the fixture (16) comprising:
a bottom plate (04) acts as a datum that supports the raw material pipe (18);
a plurality of “V” blocks (05,06,07,11) that are being fitted to the bottom plate (04) either through welding means or fastening means;
a plurality of nuts (12a,12b,12c,12d), a plurality of studs (13a,13b,13c,13d), and a “V” clamp (15) that are being provided to clamp the raw material pipe (18) over the V-blocks (05,06,07,11); and
a stopper plate (14) provided to stop the raw material pipe (18) from sliding down due to gravitational force;
wherein the plurality of “V” blocks (05,06,07,11) are of different height and placed over the bottom plate (04) in descending order to ensure a 5-degree inclination of raw material pipe (18) with the bottom plate (04).
2. The fixture (16) as claimed in claim 1, wherein the raw material pipe is having length of 1000 mm.
3. The fixture (16) as claimed in claim 1, wherein the plurality of “V” blocks comprises two fixed blocks (05,06) and two adjustable “V” blocks (07,11).
4. The fixture (16) as claimed in claim 3, wherein the fixed “V” blocks (05, 06) are being attached to the bottom plate (04) through the welding means.
5. The fixture (16) as claimed in claim 3, wherein the adjustable “V” blocks (07, 11) are being attached to the bottom plate (04) through the fastening means.
6. The fixture (16) as claimed in claim 5, wherein the fastening means employed for fitting the adjustable “V” blocks (07, 11) to the bottom plate (04), comprises a plurality of studs (8a,8b), a plurality of locknuts (9a,9b), and a plurality of guide tube (10a,10b).
7. The fixture (16) as claimed in claim 6, wherein the raw material pipe (18) is clamped with the plurality of “V” blocks (05,06,07,11) by utilizing a plurality of nuts (12a,12b,12c,12d), a plurality of studs (13a,13b,13c,13d), and a V clamp (15).
8. The fixture (16) as claimed in claim 7, wherein the stopper plate (14) is provided to stop the pipe from sliding down due to gravitational force after the cutting is completed.
9. A method (17) for producing a nozzle (02) by utilizing a fixture (16) in a Double Column Band Saw Machine (03), the method comprising the steps of:
placing a previously bored raw material pipe (18) that was step turned on both sides having length of 1000 mm at an inclination of 5° in a Double Column Band Saw Machine with the help of a fixture (16) comprising the bottom plate (04) and the plurality of “V” blocks (05,06,07,11) that facilitates in supporting the said raw material pipe (02);
clamping the said raw material pipe (18) having length of 1000 mm with the plurality of “V” blocks (05,06,07,11) by utilizing a plurality of nuts (12a,12b,12c,12d), a plurality of studs (13a,13b,13c,13d), and a “V” clamp (15);
indexing the said raw material pipe (18) having length of 1000 mm with the fixture positioned in Double Column Band Saw machine at an angle of 60°, and cutting the said pipe (18) having length of 1000 mm length into two pieces of equal length;
wherein the plurality of “V” blocks (05,06,07,11) are of different height and placed over the bottom plate (04) in descending order to ensure a 5-degree inclination of raw material pipe (18) with the bottom plate (04).