FORM 2
THE PATENTS ACT 1970 (39 OF 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION (See section 10 and rule 13)
TITLE OF THE INVENTION A SYSTEM FOR MACHINING WHEELS


APPLICANTS PREMIER LIMITED
AN INDIAN COMPANY
of 58, NARIMAN BHAWAN,
NARIMAN POINT,
MUMBAI-400 021, INDIA

The following specification particularly describes the invention and the manner in
which it is to be performed


A SYSTEM FOR MACHINING WHEELS
FIELD OF INVENTION
The present invention in general, relates to a system for machining wheels and in particular, to applying a specially designed system for machining wheels one after another consecutively, in a technically sound, automatic and uninterrupted manner, thereby reducing the handling time of wheels.
BACKGROUND OF THE INVENTION
System for machining wheels is traditionally known and it is common knowledge that such system applies conveyor mechanism for loading wheels and unloading wheels. Wheels, as will be known to persons skilled in the art, vary in size, shape and consequently mass, depending upon the application.
For example, railway wheels may have a mass of 500 Kgs and more.
Various systems for machining wheels are already known in the art adapted to machine wheels for a particular application. Further, although such systems applied conveyor mechanism for loading and unloading wheels, such systems involved, manual means to feed wheels to be machined to the machining apparatus and to remove machined wheels from the machining apparatus.
Also, such prior art systems have been found to be grossly unfit for loading, machining and unloading heavy duty wheels such as but not limited to railway wheels and the like, having a mass of 500 Kgs or more. Furthermore, the prior art systems had the disadvantage of interruption during loading and unloading wheels to and from machining apparatuses, thereby causing substantial time consumption. Additionally, the prior art systems had the vital disadvantage of lack of proper facility for locating and thereby clamping the wheels accurately for loading and unloading process. Also, the systems known in the art had complicated construction which added on to the cost of production and consequently, the cost of the final product was substantially high.
Research is on for a considerable period of time to nullify/substantially reduce the aforesaid problems in systems for machining wheels known in the art however, significant development in this regard has not been hitherto achieved.

Accordingly, there was a long felt need for a system for machining wheels which is effective in machining wheels of varying applications including but not limited to heavy duty wheels such as railway wheels and the like, involves fairly simple mechanical construction, ensures automatic uninterrupted operation, is equipped with facility for proper gripping of wheels for loading and unloading and is economic as well.
The present invention, meets the aforesaid long felt need.
All through out the specification including the claims, the words "wheels", "machining", "manipulator", "assembly", "conveyor", "frame", "clamp/clamping", "lift/ lifting", "finger(s)," "buffer", "slide", "roller" are to be interpreted in the broadest sense of the respective terms and includes all similar items in the field known by other terms, as may be clear to persons skilled in the art. Restriction/limitation, if any, referred to in the specification, is solely by way of example and understanding the present invention.
OBJECTS OF THE INVENTION
It is a principal object of the present invention to provide a system for machining wheels one after another consecutively, in an automatic and uninterrupted manner.
It is another object of the present invention to provide a system for machining wheels adapted to machine wheels of various applications.
It is yet another object of the present invention to provide a system for machining wheels, adapted to substantially reduce consumption of time during loading and unloading of wheels.
It is a further object of the present invention to provide a system for machining wheels having facility for proper gripping of wheels for loading and unloading.
It is yet another object of the present invention to provide a system for machining wheels which involves a mechanically simplified construction.

It is a further object of the present invention to provide a system for machining wheels which is adapted to load, machine and unload heavy duty wheels such as but not limited to railway wheels, having a mass of 500Kgs or more. It is a further object of the present invention to provide a system for machining wheels which is adapted to utilize gravity of the wheels, for movement of wheels during loading and unloading of wheels.
It is another object of the present invention to provide a system for machining wheels which is adapted to load, machine and unload any moment load.
It is another object of the present invention to provide a method of machining wheels one after another in an automatic and uninterrupted manner by applying a suitable machining system.
How the foregoing objects are achieved and the other aspects of the present invention, will be clear from the following description which is purely by way of understanding and not by way of any sort of limitation.
SUMMARY OF THE INVENTION
Accordingly the present invention provides a system for machining wheels including at least one means for loading wheels, at least a machining means and at least an unloading means, all said means being operatively connected to at least a clamping and lifting means, said clamping and lifting means being adapted to supply the wheels consecutively one after another to said machining means for machining, immediately after the event of removal of a machined wheel, there from in an uninterrupted manner and said manipulator means being further adapted to remove machined wheels from said machining means one by one in that order, immediately in the event of completion of machining of a wheel, by said machining means in an automatic and uninterrupted manner.
In accordance with preferred embodiments of the system of the present invention:
-said means for loading wheels includes at least a loading side conveyor, adapted to receive wheels and at least a roller conveyor adapted to center the wheels by buffer arrangement having shock absorber of hydro-spring arrangement, to take any moment load.

-said means for unloading wheels includes at least an outgoing roller conveyor adapted to center the machined wheels one after another and at least an unloading side conveyor, adapted to receive machined wheels one after another from said outgoing roller conveyor and to remove the said machined wheels from said system one after another in an automatic and uninterrupted manner.
-a conveyor frame with rollers is applied for conveying wheels one after another through out the cycle and the conveyor(s) for receiving wheels is (are) adapted to be tilted at required angle to cause movement of wheels under gravity.
-said conveyor frame is adapted to center said wheels by virtue of guide plates mounted on said conveyor(s) and said conveyor frame is adapted to be fitted on base of said conveyor(s) hinged at one end.
-the other end of said base is adapted to be attached to a hydraulic cylinder, thereby facilitating, achieving the required tilting angle of said conveyor(s) about said hinged end.
-said machining means includes suitable machinery detachably attached on at least a machining table.
-said clamping and lifting means includes a manipulator means having a plurality of arms , said means including a clamping mechanism on each said arm adapted to clamp, lift and supply wheels to said machining means immediately after the event of removal of a machined wheel from said machining means and to clamp, lift and remove wheels from said machining means, immediately in the event of completion of machining of a wheel, by said machining means.
-said manipulator means include three arms equally spaced at 120 degrees.
-said clamping mechanism includes a manipulator arm assembly having an AC servo motor with gear box for swiveling said manipulator means, said gear box having a main gear cum bearing for rotating said manipulator means, operatively connected to at least one hydraulic cylinder for lifting up and down of each said arm, on an external tube, each of said arm being adapted to be fitted on said external tube, with self lubricating bushes.

-said manipulator arm assembly further includes at least one rod attached to each end of a lifting cup, at least one clamping rod, one end of which is located on a clamping bracket, said bracket being adapted to support said clamping rod and to adjust the distance from the center of said hydraulic cylinder, whereby, the diameter of the wheels, to be clamped and lifted one after another, is achieved.
-at least one master finger is adapted to be located on said clamping rod by means of a pin, said finger being engageable with respective fingers of said wheels, thereby facilitating clamping of wheels along the respective fingers of said wheels.
-there exists two clamping rods and four said master fingers, two positioned on each clamping rod.
-said manipulator arm assembly is adapted to be fitted on a manipulator slide for its forward and backward movement, said slide being actuated by a telescopic cylinder, base of said slide being attached to said machine table, said table being adapted to be attached at 10 degrees to said system.
-said system is adapted to receive wheels in vertical direction by virtue of specially designed tilting means.
-said tilting means comprises a specially designed tilting arrangement having at least a titling station operatively connected to said conveyors and manipulator, said tilting station including a tilting base, a tilting frame, a pushing and locating arrangement and a titling cylinder.
-said tilting base has location for swiveling of tilting frame on said tilting base and there are provided holes on said base which are at compound angle and at different height, with centre axis of said holes being same.
The present invention also includes a method of machining wheels one after another in an automatic and uninterrupted manner by applying a suitable machining system including:

-loading wheels to the system one after another by applying a suitable means,
-applying a suitable means and centering the wheels one after another,
-clamping and lifting the wheels one after another by applying a specially designed manipulator means and supplying the wheels one after another in that order to a suitable machining means, immediately after removal of a machined wheel from said machining means,
-machining said wheels supplied to said machining means one after another by applying said machining means,
-applying said manipulator means again and clamping and lifting the machined wheels from said machining means in that order,
-applying outgoing rolling means and receiving the machined wheels and centering the machined wheels, so received one by one in that order,
-applying an unloading means and receiving the machined wheels from said out going rolling means and removing the machined wheels one after another in that order in an automatic and uninterrupted manner, from the system.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The nature and scope of the present invention, will be better understood from the accompanying drawings, which are by way of illustration of some preferred embodiments and not by way of any sort of limitation. In the accompanying drawings,
Figure 1 illustrates a general lay out of a preferred embodiment of the system for machining in accordance with the present invention.
Figure 1(a) illustrates a general layout of another preferred embodiment of the system for machining wheels in accordance with the present invention.
Figure 1(b) illustrates an exploded view of the titling station illustrated in the accompanying figure 1 (a)

Figure 2 illustrates an exploded view of the three arm manipulator in accordance with a preferred embodiment of the present invention.
Figure 3 illustrates a sectional view of an arm of the manipulator in declamped position, in accordance with a preferred embodiment of the present invention.
Figure 4 illustrates a sectional view of an arm of the manipulator in clamped position in accordance with a preferred embodiment of the present invention.
Figure 5 illustrates an exploded view of the conveyor frame in accordance with a preferred embodiment of the present invention.
Figure 6 illustrates an exploded view of the sliding mechanism of the manipulator, in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following describes some preferred embodiments of the present invention, which are purely for the sake of understanding the performance of the invention, and not by way of any sort of limitation.
As stated under hereinbefore under the portion "Background Of The Invention" , prior art systems for machining wheels had some well known disadvantages. The system for machining wheels, in accordance with the present invention, has been designed to nullify/substantially reduce such disadvantages. To be precise, the system for machining wheels according to the present invention, is adapted to machine wheels of varying applications including, but not limited to, heavy duty wheels such as railway wheels, one after another consecutively, in an automatic uninterrupted manner. This ensures substantial reduction in the time consumed for loading and unloading wheels. The system also involves simplified mechanical construction and hence, its cost of production is low. The system, in accordance with the present invention is equipped with facility for proper gripping of wheels for loading and unloading.

The system applies a handling device which is used to load and unload the wheels, from roller conveyor to machine and from machine to again on roller table for unloading. The system is especially used to locate wheels in accurate way on fixture and to unload wheels, again. The most encouraging aspect of the system according to the present invention is that it is applicable on wheels having varying applications including but not limited to heavy duty wheels such as railway wheels, having a mass of 500Kgs or more. Of course, it should be adequately clear to persons skilled in the art, that the system according to the present invention is equally effective for wheels having a mass less than 500Kgs.
The system includes the loading side conveyor to receive the wheel. It also includes the roller conveyor for centering the wheel by buffer type arrangement and to lift the wheel for clamping purpose with the help of lifting disc arrangement. The modern three arm manipulator is designed to use with indexing mechanism to load the wheel. The manipulator is having to and fro motion on slide base with help of telescopic hydraulic cylinder. After machining process the machined wheel is being unloaded and simultaneously, unmachined wheel is being loaded, by the three arms manipulator. It is hereby clarified that simply for the sake of understanding the invention and not by way of any limitation, a three arms manipulator has been described and illustrated herein. It should be clear to persons skilled in the art, that the manipulator may have two arms as well and similarly, the number of arms may be more than three also.
The unloaded wheel is placed on out going roller conveyor and it is re-centered on unloading station for easy movement and removal.
The operation of the system according to the present invention will be clear from the non-limiting accompanying figure 1. The operation takes place from right to left. The wheels are first loaded on the parking (1) and from there the wheels are transferred one by one consecutively to the loading station(2) and likewise, from there to the roller table(3) where the wheels are centered. The manipulator(5) clamps and lifts the wheels one by one in a consecutive manner from the roller table(3) and passes on to the machining table(4) having suitable machinery for machining wheels, thereon. Once a wheel is machined to completion, it is immediately clamped and lifted by the manipulator(5) and immediately thereafter, the latter places another wheel to be machined on the machining

table. The machined wheel is transferred to the outgoing roller table(6) where it is centered and the wheel so centered is placed on the unloading station (7). The machined wheel is thereafter, removed to the parking for unloading wheels(8). The entire process goes on for one wheel after another consecutively, in an automatic and uninterrupted manner.
In the above context it is clarified that only one parking for loading (1), one loading station(2), one roller table(3),one machining table(4), one manipulator with three arms(5), one out going roller table(6), one unloading station(7) and one parking for unloading(8) have been illustrated, only for the sake of understanding. The system may have more than one of each component described, all operatively connected to each other for proper functioning of the system and for achieving the desired objectives. Further, it is once again reiterated that the manipulator may have two arms as well and similarly, the number of arms may be more than three also, depending upon requirement.
In the aforesaid process of handling the wheels, the wheels are being transferred from one conveyor to another consecutively one by one because of the respective weight by gravity, that being the product of the mass of the respective wheel and earth's gravitational acceleration. To facilitate this, each conveyor is tilted by some angle with the help of hydraulic cylinders. Each wheel is centered with the help of robust buffer arrangement including shock absorber of hydro-spring arrangement to take any moment load. The centered wheel ready for lifting is clamped and lifted by specially made clamping fingers, as described in detail hereinafter.
At instances, wheels are introduced to the system in vertical direction instead of horizontal and to facilitate such eventuality, tilting arrangement is made to position it, in horizontal condition. General lay out of a system for machining wheels for conveying of wheels in the event of wheel coming in vertical condition is illustrated in the accompanying figure 1(a). It illustrates two tilting stations (1' ,8') for loading station(1) and unloading station(8) respectively.

The conveyors(15, 15'), the manipulator(5) and the machine(4') have the usual function, as discussed hereinbefore and hereinafter. The tilting stations (1' ,8' ) are made in such a manner, such that special equipment to put the wheel on the loading and to carry the wheel from the unloading station is not required. Instead, the wheels are carried vertically with the help of wheel escaper frame unit. Thereafter, the wheels are taken in the tilting frame of the tilting station (1' ,8') and then the wheels are made horizontal for further process as per before said manner. As shown in the accompanying figure 1(c) the tilting station station(1' ,8' ) contains tilting base(18), tilting frame(17), pushing and locating arrangement(16) and titling cylinder(19). The tilting base has location for swiveling of tilting frame on the tilting base. There are two holes on the base which are at compound angle and at different height with centre axis of two holes same. This typical hole location gives the angle required to convey wheel with the help of gravitational acceleration
According to the holes on the base the frame which is going to fit on the base is so fitted at the tilting angle. In this condition it is required to hold the wheel prior to its acceleration due to gravity. For that purpose there is a pusher mechanism in which the wheel is hold between two pushers and a rod. The force required to hold the wheel is achieved by means of hydraulic cylinder.
The accompanying figure 2, illustrates a preferred embodiment of the manipulator, in accordance with the present invention.
Each arm(5) is designed as per the wheel diameter and weight thereof, to be handled. The manipulator comprises a rigid structure, with a clamping mechanism on each arm. Each arm is equipped with at least a lifting cup(10).
The manipulator is swivelled by means of special AC servo motor(9) with gear box . The manipulator is rotated finally by means of main gear cum special bearing. The whole arm is lifted up and down on an external tube, by means of at least a hydraulic cylinder. Preferably, each arm is fitted on external tube with self lubricating bushes. The overall manipulator arm assembly is fitted on a manipulator slide which in turn slides on bottom piece with the help of telescopic cylinder, as illustrated in the accompanying figure 6.

The clamping mechanism has been further illustrated in the accompanying figures 3 and 4. This arrangement is adapted to grip the wheels accurately. Each wheel is lifted one after another in a consecutive manner, over its outer profile. The fingers(11) are made according to the profile of wheel, and fitted on the clamping rod(13). There may be at least a master finger(11) or preferably four fingers(11) two on each rod(13) for clamping of wheels.
As it will be clear from the accompanying figures 3 and 4 the clamping mechanism includes two rods(12,13) along with lifting cup(10) and hydraulic cylinder. One rod(12) is attached to lifting cup(10) one, on each side. Other end of this rod is located in the block as shown. A clamping rod(13) is located at lower side of that block and the same rod comes out from that block and is positioned on the clamping bracket. The clamping bracket is used to support the clamping rod and adjust the distance from the centre of the hydraulic cylinder, to achieve the diameter of the required wheel to be lifted/damped.
The clamping rod(13) is locked in the block by means of pin. The master finger(11) is also located on the clamping rod by means of pin.
The fingers of wheels having various applications are fitted on master(main)finger. The master finger(11) is locked, such that at zero stroke condition of hydraulic cylinder, the mechanism is in declamp condition that is fingers are in open condition. This position is illustrated in the accompanying figure 3. The stroke of the cylinder is so adjusted, that at 10 degree inclination of rod the wheel is locked by fingers. The accompanying figure 4 illustrates clamped position of the clamping assembly.
The accompanying figure 5 illustrates a preferred embodiment, where conveyor frame with rollers is used for conveying the wheels throughout the cycle. The conveyor is tilted at required degree to achieve the movement of wheels under gravity. The buffer mechanism is used with shock absorber and spring to adjust the wheels at center. The accompanying figure 5 precisely illustrates the centering mechanism(14). The block to be adjusted, is so adjusted on the guide

plate. The guide plate is mounted on the conveyor. The block is adjusted according to the diameter of the wheels. Then the wheels are lifted by lifting disc, one by one in a consecutive manner, through actuation of hydraulic cylinder. Conveyor frame fitted on the conveyor base, is hinged at one end and the other end is attached to hydraulic cylinder to get the required tilting angle about the pivot hinged point.
The accompanying figure 6 illustrates the manipulator slide. The slide facilitates the forward and backward movement of the manipulator unit. The slide is actuated by means of telescopic cylinder about 1800 mm stroke. The slide base is attached to the machine table and preferably, the machine table is attached at 10 degrees to the system.
The present invention has been described with reference to some drawings and preferred embodiments, purely for the sake of understanding and not by way of any limitation and the present invention includes all legitimate developments within the scope of what has been described hereinbefore and claimed in the appended claims.

WE CLAIM
1.A system for machining wheels including at least one means for loading wheels, at least a machining means and at least an unloading means, all said means being operatively connected to at least a clamping and lifting means, said clamping and lifting means being adapted to supply the wheels consecutively one after another to said machining means for machining, immediately after the event of removal of a machined wheel, there from in an uninterrupted manner and said manipulator means being further adapted to remove machined wheels from said machining means one by one in that order, immediately in the event of completion of machining of a wheel, by said machining means in an automatic and uninterrupted manner.
2. The system as claimed in claim 1, wherein said means for loading wheels includes at least a loading side conveyor, adapted to receive wheels and at least a roller conveyor adapted to center the wheels by buffer arrangement having shock absorber of hydro-spring arrangement, to take any moment load.
3. The system as claimed in claim 1, wherein said means for unloading wheels includes at least an outgoing roller conveyor adapted to center the machined wheels one after another and at least an unloading side conveyor, adapted to receive machined wheels one after another from said outgoing roller conveyor and to remove the said machined wheels from said system one after another in an automatic and uninterrupted manner.
4. The system as claimed in claims 2 to 3, wherein a conveyor frame with rollers is applied for conveying wheels one after another through out the cycle and the conveyor(s) for receiving wheels is (are) adapted to be tilted at required angle to cause movement of wheels under gravity.
5. The system as claimed in claim 4 wherein said conveyor frame is adapted to center said wheels by virtue of guide plates mounted on said conveyor(s) and said conveyor frame is adapted to be fitted on base of said conveyor(s) hinged at one end.

6. The system as claimed in claim 5 wherein the other end of said base is adapted to be attached to a hydraulic cylinder, thereby facilitating, achieving the required tilting angle of said conveyor(s) about said hinged end.
7. The system as claimed in claims 1 to 6 wherein said machining means includes suitable machinery detachably attached on at least a machining table.
8.The system as claimed in claims 1 to 7 wherein said clamping and lifting means includes a manipulator means having a plurality of arms , said means including a clamping mechanism on each said arm adapted to clamp, lift and supply wheels to said machining means immediately after the event of removal of a machined wheel from said machining means and to clamp, lift and remove wheels from said machining means, immediately in the event of completion of machining of a wheel, by said machining means.
9.The system as claimed in claim 8 wherein said manipulator means include three arms equally spaced at 120 degrees.
10.The system as claimed in claims 8 to 9 wherein said clamping mechanism includes a manipulator arm assembly having an AC servo motor with gear box for swiveling said manipulator means, said gear box having a main gear cum bearing for rotating said manipulator means, operatively connected to at least one hydraulic cylinder for lifting up and down of each said arm, on an external tube, each of said arm being adapted to be fitted on said external tube, with self lubricating bushes.
11.The system as claimed in claim 10 wherein said manipulator arm assembly further includes at least one rod attached to each end of a lifting cup, at least one clamping rod, one end of which is located on a clamping bracket, said bracket being adapted to support said clamping rod and to adjust the distance from the center of said hydraulic cylinder, whereby, the diameter of the wheels, to be clamped and lifted one after another, is achieved.

12.The system as claimed in claim 11 wherein, at least one master finger is adapted to be located on said clamping rod by means of a pin, said finger being engageable with respective fingers of said wheels, thereby facilitating clamping of wheels along the respective fingers of said wheels.
13.The system as claimed in claim 11 wherein there exists two clamping rods and four said master fingers, two positioned on each clamping rod.
14.The system as claimed in claims 10 to 13 wherein said manipulator arm assembly is adapted to be fitted on a manipulator slide for its forward and backward movement, said slide being actuated by a telescopic cylinder, base of said slide being attached to said machine table, said table being adapted to be attached at 10 degrees to said system.
15. The system as claimed in any preceding claim wherein said system is adapted to receive wheels in vertical direction by virtue of specially designed tilting means.
16. The system as claimed in claim 15 wherein said tilting means comprises a specially designed tilting arrangement having at least a titling station operatively connected to said conveyors and manipulator, said tilting station including a tilting base, a tilting frame, a pushing and locating arrangement and a titling cylinder.
17. The system as claimed in claim 16 wherein said tilting base has location for swiveling of tilting frame on said tilting base and there are provided holes on said base which are at compound angle and at different height, with centre axis of said holes being same.
18.A method of machining wheels one after another in an automatic and uninterrupted manner by applying a suitable machining system including:
-loading wheels to the system one after another by applying a suitable means,
-applying a suitable means and centering the wheels one after another,
-clamping and lifting the wheels one after another by applying a specially

designed manipulator means and supplying the wheels one after another in that order to a suitable machining means, immediately after removal of a machined wheel from said machining means.
-machining said wheels supplied to said machining means one after another by applying said machining means,
-applying said manipulator means again and clamping and lifting the machined wheels from said machining means in that order,
-applying outgoing rolling means and receiving the machined wheels and centering the machined wheels, so received one by one in that order,
-applying an unloading means and receiving the machined wheels from said out going rolling means and removing the machined wheels one after another in that order in an automatic and uninterrupted manner, from the system.

20 AUG 2009