Description:FIELD OF THE INVENTION

The present invention in general relates to a thermal processing equipment, specifically to heating systems designed for the production of aluminum billets. Particularly, the present invention provides a multi-log heater capable of efficiently heating multiple aluminum logs simultaneously, enabling the formation of billets of desired sizes with improved precision and energy efficiency. This invention is applicable in industries where aluminum billets are used, including but not limited to manufacturing, construction, and aerospace.

BACKGROUND OF THE INVENTION

In the aluminium processing industry, the production of billets involves heating aluminium logs to a specific temperature to achieve the desired malleability and formability. Conventional methods typically involve single-log heating systems, which can be time-consuming and inefficient, particularly in large-scale operations. These methods often suffer from inconsistent heating, leading to quality variations in the produced billets. Additionally, many existing systems are plagued by operational challenges such as uneven heating, high energy consumption, and significant maintenance requirements due to carbon generation.

The demand for high-quality aluminium billets with precise dimensions and properties has been increasing in various industries such as manufacturing, construction, and aerospace. To meet these demands, there is a pressing need for an improved heating system that can process multiple logs simultaneously while ensuring uniform temperature distribution and enhanced energy efficiency. Furthermore, the ideal system should be low-maintenance, user-friendly, and safe to operate, even by unskilled labor, to minimize operational risks and enhance productivity.

The present invention addresses these challenges by providing a modular and efficient multi-log heater specifically designed for aluminium logs. This innovative system not only optimizes the heating process and reduces energy consumption but also ensures consistent and high-quality production of aluminium billets. The heavy-duty design results in zero generation of carbon, effectively eliminating the need for maintenance. The user-friendly design is accident-proof, allowing even uneducated labor to operate it safely, with built-in overload and overheat protection to prevent accidents caused by incorrect operation. Additionally, the anti-explosion design on the top of the furnace further enhances safety by eradicating risks associated with improper handling.

Moreover, the system ensures increased longevity through the uniform application of pressure and power, reducing wear and extending its operational life. The robust structure, fabricated with ISMC 125x65x6, includes a 10-log capacity storage with hydraulic tilting, providing both durability and convenience. The use of high-quality aluminum silicate fiber for heat preservation not only saves costs but also achieves excellent thermal efficiency. The main characteristics of this system are fast heating speed, flexible production organization, and low energy consumption, making it a cost-effective and reliable solution for high-volume aluminium profile section production.

By leveraging advanced thermal management technologies, the invention offers a significant improvement over existing solutions, meeting the industry's demand for efficiency, safety, and quality in aluminium profile section production.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

These and other features, aspect, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein the device and process and digester configurations described in the present invention are explained in more detail with reference to the following drawings:

Figure 1 illustrates the external schematic view of the adaptive thermal unit.
Figure 2 illustrates the external view of emergency door.

Figure 3 illustrates the external view of storage table.

While the invention is described in conjunction with the illustrated embodiment, it is understood that it is not intended to limit the invention to such embodiment. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention disclosure as defined by the claims.

SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention nor is it intended to determine the scope of the invention.
In an aspect of the present invention, there is provided an adaptive thermal unit (17) for multiple aluminum logs comprising:
a mild-steel (hot rolled sheets) structure from the outside and stainless steel (SS 304) structure from the inside comprising a rectangular thermal unit (18) with Log Out door (1) at the back side connected to a storage table (16) assembled to form a rectangular box-table shape as a hybrid assembly;

an external roof structure of the rectangular thermal unit (18) comprising Pneumatic Cylinder Sensor (2) at the edge adjoining the front side and the roof of adaptive thermal unit (17), an exit door (3), a burner (4), ID Fan (5), Chimney (6), a Blower (7), a flame sensor (10), a safety valve (11) and an ignition sensor (12);

an external side structure of the rectangular thermal unit (18) at the right side of the Log Out Door (1) comprising a plurality of side doors (8), a plurality of Thermocouple sensors (9), a log roller chain conveyor (14) and a log tilting (15); and

an external side structure of the rectangular thermal unit (18) at the back side of the Log Out Door (1) comprising an emergency door (13).

In an embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the outer walls are made up of mild-steel (hot rolled sheets) and inners walls are made up of stainless steel (SS 304).

In another embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the thermal unit (17) is provided with aluminum round bar placed on the log storage table (16).

In yet another embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the aluminum round bar enters into the thermal unit through a Log Out Door (1).

In still another embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the thermal unit (17) comprises a Pneumatic Cylinder Sensor to control the opening and closing of Log Out Door (1).

In an embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the thermal unit (17) further comprises a Burner (4) to heat up the aluminum log at a certain pre fixed temperature, which is calculated as per the desired size of the billets, ID Fan (5) for hot air circulation inside the thermal unit (17).

In another embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the thermal unit (17) comprises a chimney (6) installed at its roof acting as a regenerative system for sucking in hot air which is being escaped, a blower (7) connected as an inlet connection providing oxygen to the thermal unit (17) for effective combustion.

In yet another embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the thermal unit (17) further comprises thermocouple sensor (9) to sense the temperature inside the unit, a flame sensor (10) affixed with burner (4) to monitor the burner (4).

In still another embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the ignition sensor (12) is provided to ignite the burner (4), safety valve (11) is installed in the thermal unit (17) to release the extra pressure.

In an embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the thermal unit (17) further comprises a side door (8) to see through what is happening in the unit (17) and the emergency door (13) to be used in case of die failure.

In another embodiment of the present invention, there is provided an adaptive thermal unit (17), wherein the thermal unit (17) comprises the log roller chain conveyor (14) installed outside the unit (17), and the log tilting (15) to auto tilt the loaded log by hydraulic cylinder.

These and other features, aspects, and advantages of the present subject matter will be better understood with reference to the following description. This summary is provided to introduce a selection of concepts in a simplified form.

DETAILED DESCRIPTION OF THE INVENTION

Those skilled in the art will be aware that the present disclosure is subject to variations and modifications other than those specifically described. It is to be understood that the present disclosure includes all such variations and modifications. The disclosure also includes all such steps of the process, features of the invention, referred to or indicated in this specification, individually or collectively, and any and all combinations of any or more of such steps or features.

Definitions
For convenience, before further description of the present disclosure, certain terms employed in the specification, and examples are collected here. These definitions should be read in the light of the remainder of the disclosure and understood as by a person skilled in the art. The terms used herein have the meanings recognized and known to those of skill in the art, however, for convenience and completeness, particular terms and their meanings are set forth below.

The articles “a”, “an” and “the” are used to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. The terms “comprise” and “comprising” are used in the inclusive, open sense, meaning that additional elements may be included. It is not intended to be construed as “consists of only”. Throughout this specification, unless the context requires otherwise the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference. The present disclosure is not to be limited in scope by the specific embodiments described herein, which are intended for the purposes of exemplification only. Functionally equivalent products and methods are clearly within the scope of the disclosure, as described herein.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

While the invention is susceptible to various modifications and/or alternative adaptations, specific embodiments thereof has been shown by way of examples and will be described in detail below. However, it should be understood, that it is not intended to limit the invention to the particular structural arrangement disclosed, but on the contrary, the invention is to cover all modifications, structural adaptations and alternative falling within the spirit and the scope of the invention as defined herein.

The present invention in general relates to a thermal processing equipment, specifically to heating systems designed for the production of aluminum billets. Particularly, the present invention provides a multi-log heater capable of efficiently heating multiple aluminum logs simultaneously, enabling the formation of billets of desired sizes with improved precision and energy efficiency. This invention is applicable in industries where aluminum billets are used, including but not limited to manufacturing, construction, and aerospace.

Thus, in accordance with the present invention there is provided an adaptive thermal unit (17) for multiple aluminum logs comprising:
a mild-steel (hot rolled sheets) structure from the outside and stainless steel (SS 304) structure from the inside comprising a rectangular thermal unit (18) with Log Out door (1) at the front side connected to a storage table (16) assembled to form a rectangular box-table shape as a hybrid assembly;

an external roof structure of the rectangular thermal unit (18) comprising Pneumatic Cylinder Sensor (2) at the edge adjoining the front side and the roof of adaptive thermal unit (17), an exit door (3), a burner (4), ID Fan (5), Chimney (6), a Blower (7), a flame sensor (10), a safety valve (11) and an ignition sensor (12);

an external side structure of the rectangular thermal unit (18) at the right side of the Log Out Door (1) comprising a plurality of side doors (8), a plurality of Thermocouple sensors (9), a log roller chain conveyor (14) and a log tilting (15); and

an external side structure of the rectangular thermal unit (18) at the left side of the Log Out Door (1) comprising an emergency door (13).

Figure 1 is an adaptive thermal unit that is constructed in accordance with a preferred embodiment of the present invention. The present invention relates to an adaptive thermal unit (17) specifically designed for heating multiple aluminium logs, enhancing safety, efficiency, and precision in the thermal treatment process. The adaptive thermal unit features a robust construction with an outer structure made from mild steel (hot rolled sheets) and an inner structure made from stainless steel (SS 304). The primary component is a rectangular thermal unit (18) with a Log Out door (1) at the front, connected to a storage table (16) illustrated in Figure 3, forming a hybrid box-table shape that optimizes space and functionality.

The external roof of the rectangular thermal unit (18) incorporates several critical components for operational control and safety. These include a Pneumatic Cylinder Sensor (2) located at the edge adjoining the front side and the roof, an exit door (3) for maintenance and repair, a burner (4), an ID Fan (5) for internal air circulation, a chimney (6) for exhaust, a blower (7) for air supply, a flame sensor (10), a safety valve (11), and an ignition sensor (12).

On the right side of the Log Out door (1), the external structure features multiple side doors (8) for inspection, Thermocouple sensors (9) for temperature monitoring, a log roller chain conveyor (14), and a log tilting mechanism (15) for handling and positioning the logs. The left side includes an emergency door (13), illustrated in figure 2, for safety and quick access in case of die failure or alloy changes.

In terms of material and construction, the outer walls of the thermal unit are made of mild steel, while the inner walls are constructed from stainless steel (SS 304), providing durability and resistance to high temperatures. Aluminium rods are stored on the log storage table (16) and enter the thermal unit through the Log Out door (1), which is controlled by a Pneumatic Cylinder Sensor (2) to ensure safe and efficient operation.

The burner (4) heats the aluminium logs to a predetermined temperature, regulated by Thermocouple sensors (9) and controlled by a PLC system. The burner operates at varying speeds, with two solenoid valves ensuring precise temperature maintenance. The ID Fan (5) circulates hot air inside the unit, while the chimney (6) serves as a regenerative system to recapture escaping hot air, enhancing energy efficiency. The blower (7) supplies necessary oxygen for combustion.

The thermal unit is equipped with multiple safety mechanisms, including a flame sensor (10) to monitor the burner, an ignition sensor (12) for burner ignition, and a safety valve (11) to release excess pressure. Side doors (8) and an emergency door (13) provide access for inspection and emergency situations. The log roller chain conveyor (14) and log tilting mechanism (15) automate the movement and positioning of logs, controlled by a hydraulic cylinder for precise operation.

The electric panel consists of a Programmable Logic Controller (PLC) that manages the operation of the thermal unit. It receives input regarding the size of billets and calculates the necessary temperature. The PLC controls the burner, adjusting its operation based on real-time temperature readings from Thermocouple sensors (9), ensuring optimal performance and safety.

In more detail, the Log Out door is equipped with a sensor controlled by the PLC, ensuring the door opens fully before logs are extracted, preventing accidents. A Pneumatic Cylinder is used to open and close the Log Out door, controlled by the PLC for precise operation. The exit door is manually operated for maintenance access, ensuring safety and ease of repair. The double stage burner automatically adjusts between low and high speeds, controlled by PLC for safe and efficient heating.

The ID Fan, made of SS-304, draws air inside and circulates it to maintain uniform temperature and reduce fuel costs. The chimney includes a regenerative system to optimize heat use and ensure safety by coordinating with the burner and PLC. A blower provides necessary air to the burner, playing a crucial role in combustion. Side doors allow inspection and troubleshooting without interrupting the process. Thermocouple sensors monitor internal temperature, enabling precise control of the heating process. The flame sensor continuously monitors the burner, ensuring it operates safely. A safety valve releases excess air pressure, controlled by the PLC to maintain safe operation. The ignition sensor ensures the burner ignites safely and efficiently.

The emergency door provides a quick exit for logs in case of emergencies, such as die failure or alloy changes. The log roller chain conveyor facilitates smooth movement of logs, with cooling provided by a blower. The log tilting mechanism automates log tilting using a hydraulic cylinder, enhancing efficiency. The log storage table is designed to hold up to 10 logs, with a heavy-duty frame for stability.

The adaptive thermal unit (17) represents a significant advancement in the field of aluminium treatment, combining safety, efficiency, and precision to meet the demanding requirements of modern industrial processes.

Regenerative System: The incorporation of a regenerative system, including the chimney, significantly enhances the energy efficiency of the thermal unit. This system captures and recycles escaping hot air, ensuring that the maximum amount of heat is utilized within the unit, thereby reducing waste and improving overall thermal efficiency.

Energy Consumption: The adaptive thermal unit is designed to consume less energy due to its efficient design and advanced control systems. The use of high-quality insulation materials, precise temperature control, and the regenerative system all contribute to minimizing energy consumption while maintaining optimal performance.

Enhanced Safety through PLC-Controlled Valve: A critical safety feature of the thermal unit is the valve connected to the PLC. This valve opens before the burner is ignited and automatically closes once the burner starts, preventing any potential accidents. This pre-emptive safety measure ensures that the system is free of any accumulated gases before ignition, reducing the risk of explosions or other safety hazards.

Fuel Efficiency: The thermal unit is equipped with a double-stage burner that operates efficiently across a range of speeds. The burner automatically adjusts to low and high speeds as required, maintaining the set temperature with minimal fuel consumption. This intelligent control mechanism, combined with the regenerative system, ensures that the unit operates with maximum fuel efficiency, reducing operating costs and environmental impact.

Production Increase: The adaptive thermal unit is capable of handling multiple logs simultaneously, with automated features such as the log roller chain conveyor and hydraulic log tilting mechanism. These features streamline the loading and unloading process, reducing downtime and significantly increasing overall production efficiency.

Uniform Heating: The design of the thermal unit ensures that the aluminium logs are heated uniformly. The ID Fan circulates hot air evenly throughout the unit, preventing hotspots and ensuring consistent temperature distribution. This uniform heating is crucial for achieving high-quality billets with optimal mechanical properties.

Shiny Material: By maintaining a consistent and precise temperature, the thermal unit enhances the quality of the aluminium extrusion profiles. The uniform heating process improves the brightness and hardness of the profiles, resulting in shiny, aesthetically pleasing material with superior mechanical properties.

Improved Profile Quality: The thermal unit ensures high-quality extrusion profiles by providing uniform heating, which enhances both the aesthetic and mechanical properties of the aluminium profiles.

Durable Construction: The combination of mild steel for the outer structure and stainless steel (SS 304) for the inner structure ensures the thermal unit's durability and longevity. This robust construction withstands the high temperatures and harsh conditions typical of industrial environments, providing reliable performance over an extended period.

Enhanced Die Life: The uniform heating provided by the thermal unit not only improves the quality of the aluminium profiles but also extends the life of the extrusion dies. Consistent temperature control reduces thermal stress on the dies, minimizing wear and tear and lowering maintenance costs.

Advanced Control System: The integration of a PLC with sensors and automated controls allows for precise management of the thermal unit's operations. This advanced control system ensures that all processes are monitored and adjusted in real-time, enhancing safety, efficiency, and overall performance.
, Claims:We Claim:

1. An adaptive thermal unit (17) for multiple aluminum logs comprising:

a mild-steel (hot rolled sheets) structure from the outside and stainless steel (SS 304) structure from the inside comprising a rectangular thermal unit (18) with Log Out door (1) at the front side connected to a storage table (16) assembled to form a rectangular box-table shape as a hybrid assembly;

an external roof structure of the rectangular thermal unit (18) comprising Pneumatic Cylinder Sensor (2) at the edge adjoining the front side and the roof of adaptive thermal unit (17), an exit door (3), a burner (4), ID Fan (5), Chimney (6), a Blower (7), a flame sensor (10), a safety valve (11) and an ignition sensor (12);

an external side structure of the rectangular thermal unit (18) at the right side of the Log Out Door (1) comprising a plurality of side doors (8), a plurality of Thermocouple sensors (9), a log roller chain conveyor (14) and a log tilting (15); and

an external side structure of the rectangular thermal unit (18) at the left side of the Log Out Door (1) comprising an emergency door (13).

2. The adaptive thermal unit (17) as claimed in claim 1, wherein the outer walls are made up of mild-steel (hot rolled sheets) and inners walls are made up of stainless steel (SS 304).

3. The adaptive thermal unit (17) as claimed in claims 1-2, wherein the thermal unit (17) is provided with aluminum round bar placed on the log storage table (16).

4. The adaptive thermal unit (17) as claimed in claim 1, wherein the aluminum round bar enters into the thermal unit through a Log Out Door (1).

5. The adaptive thermal unit (17) as claimed in claim 1, wherein the thermal unit (17) comprises a Pneumatic Cylinder Sensor to control the opening and closing of Log Out Door (1).

6. The adaptive thermal unit (17) as claimed in claim 1, wherein the thermal unit (17) further comprises a Burner (4) to heat up the aluminum log at a certain pre fixed temperature, which is calculated as per the desired size of the billets, ID Fan (5) for hot air circulation inside the thermal unit (17).

7. The adaptive thermal unit (17) as claimed in claim 1, wherein the thermal unit (17) comprises a chimney (6) installed at its roof acting as a regenerative system for sucking in hot air which is being escaped, a blower (7) connected as an inlet connection providing oxygen to the thermal unit (17) for effective combustion.

8. The adaptive thermal unit (17) as claimed in claim 1, wherein the thermal unit (17) further comprises thermocouple sensor (9) to sense the temperature inside the unit, a flame sensor (10) affixed with burner (4) to monitor the burner (4).

9. The adaptive thermal unit (17) as claimed in claim 1, wherein the ignition sensor (12) is provided to ignite the burner (4), safety valve (11) is installed in the thermal unit (17) to release the extra pressure.

10. The adaptive thermal unit (17) as claimed in claim 1, wherein the thermal unit (17) further comprises a side door (8) to see through what is happening in the unit (17) and the emergency door (13) to be used in case of die failure.

11. The adaptive thermal unit (17) as claimed in claim 1, wherein the thermal unit (17) comprises the log roller chain conveyor (14) installed outside the unit (17), and the log tilting (15) to auto tilt the loaded log by hydraulic cylinder.