A TUBE BENDING CONNECTOR AND A METHOD THEREOF

FIELD OF THE INVENTION
[0001] The present subject matter described herein relates to tube bending. More specifically, the present invention relates to a connector to connect tubes for performing a method of automatic tube bending.

BACKGROUND OF THE INVENTION
[0002] 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.
[0003] Coils are pressure part components in thermal boilers that carry high pressure steam to turbines. They are a set of hollow tubes that are kept in a pre-designed sequence called circuits with necessary attachments. The coils are assembled as a unit inside the boiler of a thermal power plant. The circuits are of different lengths. Various sizes of end limbs are used for the coil depending on the design of the thermal boilers.
[0004] The end limbs connect with the header and the coil to transmit steam and water in the power plant. So it can be said that the bend angle and length are more important in the boiler design. It is also a very important aspect to consider under boiler regulations for safety measures. Hence, no deviation is allowed for any bend. Therefore, any defective bend in the circuit should be rectified or taken out.
[0005] In existing designs, a system bender machine is used. It works based on automatic programming. But the end limb bending is done by manual process due to the insufficient length of the tube. The minimum tube length required between transporter to former for the automatic bending process is 3000 mm. The end limb had 300 – 500 mm length only. Due to that reason, end limb bending is done by manual operation. After completing all bends by automatic bending process except last end limb, the machine is returned to manual mode.
[0006] For manual mode, the tube transporter is not able to draw a tube. So it has to be dragged by at least four people to takeout from former to flipping purpose for flippling the unfinished circuit for the required direction of the bend. So usually, a crane is used to flip the circuit and load on the table for marking.
[0007] After completing the marking, four people drag the tube to the former and thereby locate the marked area. Fine adjustments are made manually to pull or push the tube to the former perfectly. More time is taken for fine adjustment. After holding by former, the bend done by manual mode operation. The angle of bend and tube measurements are unequal due to manual process. Therefore, for rectifying the unequal bends, Such hot correction are made. Due to this rework, more manpower usage, Liquified Petroleum Gas (LPG) and oxygen are used leading to less productivity and poor quality.
[0008] Moreover, frequent issues are faced in manual bending while draging and flipping the coil results in high operator fatigue. This process involves more machine idle time due to more time to drag the tube, circuit flipping and circuit positioning in former, more manpower usage and more material wastage.
[0009] It is thereby required to develop a connector to facilitate in bending all lengths of the tube, whether it be long or short.
OBJECTS OF THE DISCLOSURE
[0010] It is therefore the object of the present disclosure to overcome the aforementioned and other drawbacks in prior arts.
[0011] It is a primary object of the present disclosure to provide a tapered connector to facilitate automatic end limb tube bending instead of manual bending.
[0012] It is another object of the present disclosure to aid in cost effective way of bending short length tubes.
[0013] It is another object of the present disclosure to provide the connector that is simple, lightweight and efficient.
[0014] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taken into consideration with accompanying drawings in which preferred embodiments of the present subject matter are illustrated.
SUMMARY OF THE INVENTION
[0015] One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus/composition and a method as claimed in the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be part of the claimed disclosure.
[0016] Solution to one or more drawbacks of existing technology and additional advantages are provided through the present disclosure. Additional features and advantages are realized through the technicalities of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered to be a part of the claimed disclosure.
[0017] The present disclosure offers a solution in the form of connector for connecting a first tube with a second tube to perform a bending process. It includes a middle section extending and forming a plurality of segments wherein one segment is located on left side and the other segment is located on right side of the middle section, wherein the segments are tapered in which diameter of the segments decreases from the middle section along the length till the end of the segments.
[0018] In an aspect of the invention, the first tube is a bending tube.
[0019] In a further aspect of the invention, the second tube is a trailing tube.
[0020] In an aspect of the invention, the left segment and the right segment are conical.
[0021] In an aspect of the invention, the middle section has a semi-circular notch.
[0022] In an aspect of the invention, the semi-circular notch is present on the top and the bottom portion of the the middle section.
[0023] In an aspect of the invention, the first tube and the second tube are hollow and are configured to insert the connector through an interior passageway.
[0024] In yet another aspect of the invention, a method for bending a first tube and a second tube is given. It includes inserting a connector through an interior passageway of a first tube and a second tube and sending the first tube to a bending machine for performing automatic bending, wherein the automatic bending is controlled by a control unit that commands the bending machine to bend the first tube for a predefined interval of time and the connector disconnects with the second tube using a machine transporter after bending is performed on the first tube.
[0025] 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.
[0026] 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.
[0027] 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.
[0028] 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
[0029] 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:-
[0030] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the present disclosure may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0031] Fig. 1 illustrates tubes connection with a connector according to the present disclosure;
[0032] Fig. 2 (a) illustrates a front view of the connector according to the present disclosure;
[0033] Fig. 2 (b) illustrates a side view of the connector according to the present disclosure;
[0034] Fig. 3 illustrates a method according to the present disclosure.
[0035] 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.
[0036] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAIL DESCRIPTION OF INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS OF THE PREFERRED EMBODIMENTS:
[0037] 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.
[0038] 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 such 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 or device.
[0039] The present invention is related to end limb bending of a bending tube with the help of a trailing tube by using a connector that is situated in between the two hollow tubes.
[0040] Referring to Figure 1 and Figure 2, it shows the connector (100). The connector (100) is basically a mandrel and is formed of a middle section (103) and two segments (104, 105). The connector constitutes a single piece and is made of a material including mild steel. The connector (100) is made by a method where the mild steel round bar is turned by lathe as per the dimension, after the hardening process is done.
[0041] The middle section (103) has a notch or depression of surface at its center. The middle section (103) is extended in left side and right side forming the left segment (104) and the right segment (105). The connector (100) is inserted inside the first tube (101) and the second tube (102). The connector (100) and the tubes (101, 102) are not limited to a single size. Further, the diameter and length of the connector (100) and the tubes (101, 102) may vary depending upon the requirement.
[0042] The material above has been given as an example without restricting scope of the invention to the same. Thus, other materials readily apparent to a person skilled in the art are understood to be within scope of the invention.
[0043] The middle section (103) forms a semi-circular notch at the top portion as well as the bottom portion. The middle section (103) is further extended in the left side and the right side forming a tapered segments (104, 105) or the left segment (104) and a right segment (105).
[0044] The left segment (104) and the right segment (105) are tapered and have a conical surface. Further, the conical surface of the left segment (104) and the right segment (105) have an outer peripheral surface defining diameter of the segments (104, 105). The half of the left segment (104) and the right segment (105) define radius.
[0045] The diameter of the conical surface of the left segment (104) and the right segment (105) is larger at one end where they are connected to the middle section (103). The diameter decreases along the longitudnal length of the conical segments (104, 105) till the end.
[0046] The segments (104, 105) are inserted in the hollow tubes (101), (102). The first tube (101) is a bending tube, that is sent to the bending machine to perform the bending process. The second tube (102) is a trailing tube. The first tube (101) and the second tube (102) are hollow and the connector (100) is inserted inside the inner passageway of the first tube (101) and the second tube (102). The connector (100) is used to maintain the second tube (102) as a continuation of the first tube (101) and the connector (100) also maintains the required length for the bending process.
[0047] Basically, after using the connector (100) between the first tube (101) and the second tube (102), the activities of dragging the tubes (101, 102), circuit flipping, marking and circuit positioning to the tubes (101, 102) are eliminated.
[0048] In an embodiment, the size of the first tube (101) and the second tube (102) is not limited to a single size and change. Similarly, the connector (100) size is also not limited to a single size. The sizes of the tubes (101), (102) may vary and change depending upon the requirement.
[0049] Referring to Figure 3, a method (300) of connecting the two tubes (101, 102) rigidly to perform bending process is shown. In the first step (301), the connector (100) is inserted inside the interior passageway of first tube (101) and the second tube (102) that are hollow. The first tube (101) is bending tube and the second tube (102) is trailing tube. The first tube (101) is the one that is sent for bending in the bending machine. The connector (100) is inserted manually by an operator. The connector (100) after the insertion, stops the place or diameter on the first segment (104) and the second segment (105) that is equal to the diameter of the first tube (101) and the second tube (102).
[0050] In the second step (300), the first tube (101) that is bending tube is sent to the bending machine for automatic bending with the help of a control unit. The control unit bends the first tube (101) at a predefined level set according to the requirement that commands the bending machine to bend the first tube (101) and for a predefined interval of time. Using this connector (100), the limb bending is done without any requirement of the manual process that is required to be done by the operator. Here, in this step, the degree variation and dimension variation is avoided because of automatic system control. Hence circuit flipping is eliminated, and crane usage is eliminated.
[0051] After the bending process is performed on the first tube (101), the connector (100) is disconnected and released from the second tube (102) automatically using a machine transporter and the first tube (101) gets completely bend without any defect.
[0052] By using this method (300), the tapered connector (100) is able to be easily located in any tube that is not limited to a single size and perform end limb automatic bending with lesser effort. Thereby the productivity is enhanced and the cost of bending is reduced.

WORKING OF INVENTION
[0053] The connector is fixed between the first tube (101) and the second tube (102) by the operator. The connector is easy to fix with second tube (102) which is a trailing tube due to the design of the connector. Afterwards the first tube (101) is sent for automatic bending in the bending machine. The Automatic bending method is controlled by a control unit. Automatic tube bending ensures dimensions and angles of bend as predetermined on a reference drawing. The connector is further released or withdrawed from the second tube (102) by a machine transporter. Tube connector is used between tubes (101), (102) will eliminate the manual bending time and improve the productivity.
TEST RESULT
[0054] The total cycle time for bending is reduced by 30% from the conventional process and productivity is improved. Inspection process is eliminated by the automatic bending process which is controlled by machine itself. General dimensions of the circuits are also checked in coil assembly inspection.
TECHNICAL ADVANTAGES
[0055] With the help of the solution as proposed herein in the context of the present disclosure, the total cycle time is reduced, productivity is improved, rework is eliminated and bend quality is ensured.
[0056] The end limb bending of the tube is done automatically without manual operations.
[0057] The activities of dragging the tube, circuit flipping, marking and circuit positioning to the tubes are eliminated.
[0058] 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 disclosures 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. Also, 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 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 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.”
[0059] It will be further appreciated that functions or structures of a plurality of components or steps may be combined into a single component or step, or the functions or structures of one-step or component may be split among plural steps or components. The present disclosure contemplates all of these combinations. Unless stated otherwise, dimensions and geometries of the various structures depicted herein are not intended to be restrictive of the disclosure, and other dimensions or geometries are possible. Also, while a feature of the present disclosure may have been described in the context of only one of the illustrated embodiments, such feature may be combined with one or more other features of other embodiments, for any given application. It will also be appreciated from the above that the fabrication of the unique structures herein and the operation thereof also constitute methods in accordance with the present disclosure. The present disclosure also encompasses intermediate and end products resulting from the practice of the methods herein. The use of “comprising” or “including” also contemplates embodiments that “consist essentially of” or “consist of” the recited feature.
[0060] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0061] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.
[0062] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particulars claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogues to “at least one of A, B and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B”.
[0063] The above description does not provide specific details of manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[0064] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0065] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[0066] 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.

WE CLAIM

1. A connector (100) for connecting a first tube (101) with a second tube (102) to perform a bending process, the connector (100) comprising of:
a middle section (103) extending and forming a plurality of segments (104, 105),
wherein one segment (104) is located on left side and the other segment (105) is located on right side of the middle section (103),
wherein the segments (104, 105) are tapered in which diameter of the segments decreases from the middle section (103) along the length till the end of the segments (104, 105).
2. The connector (100) as claimed in claim 1, wherein the first tube (101) is a bending tube.
3. The connector (100) as claimed in claim 1, wherein the second tube (102) is a trailing tube.
4. The connector (100) as claimed in claim 1, wherein the left segment (104) and the right segment (105) are conical.
5. The connector (100) as claimed in claim 1, wherein the middle section (103) has a semi-circular notch.
6. The connector (100) as claimed in claim 1, wherein the semi-circular notch is present on the top and the bottom portion of the the middle section (103).
7. The connector (100) as claimed in claim 1, wherein the first tube (101) and the second tube (102) are hollow and are configured to insert the connector (100) through an interior passageway.
8. A method (300) for automatically bending a first tube (101) and a second tube (102), the method (300) comprises of steps:
inserting (301) a connector (100) through an interior passageway of a first tube (101) and a second tube (102); and
sending (302) the first tube (101) to a bending machine for performing automatic bending,
wherein the automatic bending is controlled by a control unit that commands the bending machine to bend the first tube (101) for a predefined interval of time,
wherein the connector (100) disconnects with the second tube (102) using a machine transporter after bending is performed on the first tube (101).