Description:

FIELD OF THE INVENTION:
[001] The present invention relates to a method for manufacturing process on pressure part in boiler circuit like “Dished end”. This new device used to press and removal of the boiler fittings to reduce the operator fatigue and total cycle time. The same can be used to the process of pressing and removal of dished end for different diameter.

BACKGROUND/PRIOR ART 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] Dished ends are the major component in the headers and the drums in the boiler circuit. The ends of the drums and headers are covered by dished ends. The dished ends come in various shapes and sizes. The shape of the dished ends is either semi-ellipsoidal or hemispherical. The hemispherical dished ends have higher thickness at the skirt region than the crown region. The semi-ellipsoidal dished ends have largely uniform thickness from crown to skirt region.

[004] The main components of the dished ends hot forming are forming ring along with spacer and the bullet. The bullet controls the inner diameter of the dished ends and the forming ring controls the outer diameter of the dished ends. The spacer is used to clamp the forming ring to the ram of the press. The bullet is kept stationary at the bottom.

[005] The bullet is to be kept in such a way that the bullet is in centre with the forming ring and the spacer. This is must for the formation of the dished ends uniformly along its circumference. If the centre is not aligned properly then the material flow will be more in one direction thereby resulting in the rejection of the dished ends.

[006] The blanks are to be loaded in the furnace then heated to the required temperature and required soaking is maintained, the blanks can be taken out for hot forming. The blanks are placed over the bullet and the forming ring is operated in the downward direction. The forming ring along with the spacer presses the dished end blank to form over the bullet. The dished ends blank acquires the shape of the bullet.

[007] After hot forming the dished end along with the bullet is taken out and kept in the open for cooling where the cooling process takes minimum 11 hrs. After cooling the dished end is remains stuck with the bullet.

[008] For dished end removal process the top spacer is loaded onto the press by the means of forklift. The top spacer is clamped to the ram of press by means of bolts. After the clamping of top spacer, the bottom spacer is placed on the bed of the press by means of forklift. The ram of the press is moved upward. The dished ends together with the bullet are loaded onto the press by means of crane. The ram is operated downward and the skirt of the dished ends are pressed multiple times which results in opening of dished ends. The clearance is obtained between the dished end and the bullet and the dished ends are removed successfully from the bullet.

[009] The problems that arise in removing these dished ends from the bullet are as following:-
1. The dimension of the dished end will not be uniform as the dished ends are pressed throughout the circumference while removal process. This pressing will result in uneven dimension of the dished ends.
2. There is a possibility of giving overload on the dished ends
3. The cracks can propagate even if slight overload is given.
4. After pressing the surface will be found of scars thus grinding is required after dished ends pressing.
5. The safety of the operator is not ensured throughout the operation as the top spacer clamped to the ram of the press can move towards while pressing. These above are the problems while removal of smaller dished ends.
6. Hot formed dished end cooling process take more time.

[0010] In view of the above, there is requirement to devise an assembly which can address the aforesaid shortcoming(s). Hence, the present invention has been introduced.

OBJECTS OF THE INVENTION:

[0011] It is therefore an object of the present subject matter to overcome the aforementioned and other drawbacks in the solutions available in state-of-the-art.
[0012] An object of the present invention is to provide an apparatus to avoid a bullet center setting for each pressing process.
[0013] Another object of the present invention is to provide an apparatus to avoid cooling process after hot forming of dished end with bullet.
[0014] Another object of this invention is to provide an apparatus a top plate and spacer setting process for dished end removal purpose.
[0015] Another objective of this invention is to provide an apparatus to eliminate the uneven outer surface of dished end while pressing on removal process.
[0016] Another objective of this invention is to provide a method to reduce operator fatigue while dished end removal process.
[0017] Another objective of this invention is to provide a method to reduce the rejection of material due to crack occur while removal pressing process.
[0018] Another objective of this invention is eliminating air pollution to avoid cooling and rework grinding process.
[0019] Still another objective of this invention is to reduce crane engagement during removal process.
[0020] One more objective of this invention is to reduce cycle time for dished end pressing and removal process.
[0021] Yet another objective of this invention is to increase the productivity of dished ends.
[0022] 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 taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.

SUMMARY OF THE INVENTION:

[0023] 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.
[0024] This apparatus is used to easily remove the dished end from bullet to utilize the available heat energy.
[0025] Accordingly, split ring part- a welded on base plate and split ring part -b is movable on base plate. Both split rings is used to lock the bottom of bullet with exact center position on base plate. Connecting hooks are welded on outer surface of the top die and forming die. This connecting hook is the provision to lock the connecting plate while dished end removal process. U shape plate is inserted between hot formed dished end and forming die while removing process.
[0026] However, this assemble of new device use to eliminate the cooling process time and operator fatigue while removal of boiler fitting dished ends.
[0027] The present invention is achieved by the features of principal claim and subsequent claims.
[0028] 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.
[0029] 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.
[0030] 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:

[0031] 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:-
[0032] Figure 1 shows the boiler fitting pressure parts component dished end.
[0033] Figure 2 shows the forming bullet.
[0034] Figure 3 shows the dished end hot forming process (old method).
[0035] Figure 4 shows the dished removal process from bullet (old method).
[0036] Figure 5 shows the drawing of split rings part – a& b (new method bullet locking device).
[0037] Figure 6 shows the drawing of base plate welded with split ring part- a.
[0038] Figure 7 shows the shows the connecting device (item 7&9) while new removal process.
[0039] Figure-8 shows the U plate used for new removal process.
[0040] Figure-9 shows the new apparatus setting and initial pressing process.
[0041] Figure-10 shows the dished end hot forming process in new method.
[0042] Figure-11 shows the dished end removal process using new apparatus.

[0043] 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.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S) OF THE PRESENT INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS:

[0044] While the embodiments of the disclosure are subject to various modifications and alternative forms, specific embodiment thereof have 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 alternative falling within the scope of the disclosure.
[0045] The present invention makes a disclosure regarding a technology pertinent to an assembly used to easily remove the dished end from bullet to utilize the available heat energy.
[0046] Now reference may be made to Figure-9 illustrating the new apparatus setting and initial pressing process. Step-1 and step-2 of initial process are described in figure-9.
[0047] Now referring to Figure-10 showing the dished end hot forming process in new method. Step-3 and step-4 of the process claimed in the present invention is described in figure-10.
[0048] Figure- 11 shows the dished end removal process using new apparatus. Step-5 and step-6 of the process claimed in the present invention is described in figure-10.
[0049] The Present invention relates to a manufacturing process on pressure part in boiler circuit like “Dished end”. Before start the dished end (10) hot forming process, set the new base plate (13) welded with split ring (fig-6) is located on bottom bed (5) of the pressing machine. And the split ring (fig-6) is calmed at the center of the bed by using bolt and nut with bottom bed (5).
[0050] Forming bullet (11) bottom side square grove provision is available for bullet (11) handling purpose, the bullet (11) bottom portion is insert to the split ring (12 part- a) and locked with movable split ring (fig 5 part-b), now bullet (11) bottom portion rigidly clamped by split rings(12 a &b) at exact center of machine (fig-9).
[0051] Top die (1) and forming die (2) also set the exact center of the machine top plate (4) by using bolt and nut. Here forming die (2) is locked with top die (1) by using lock pin (3).
[0052] After completion of bullet (11) and forming die (2) setting process at pressing machine, the temperature 940-970 º C heated dished end (10) blank is kept out from furnace and locate the top of the bullet (11) for dished end (10) hot forming process.
[0053] Machine top portion is moved to downward direction along with top die (1) and forming die (2).
[0054] The forming die (2) pressing the heated blank to downward direction of the ram of the press up to complete formation of dished end (10) shape, while hot forming the bullet (11) controls the inner diameter of the dished end (10) and the forming ring (2) controls the outer diameter of the dished end (10). While pressing the bullet (11) is kept stationary at the bottom by rigid clamping of new base plate (13) and split ring arrangements (fig 5- a& b).
[0055] The bullet (11) is to be kept in centre with the forming ring (2) while hot forming. Now dished end (10) gets the uniform formation along its circumference in this new method. Here centre is not aligned so we avoid the rejection of the dished ends (10).
[0056] After dished end (10) hot forming completed on lock pin (3) is released, now forming die (2) is separate from top die (1). Now forming die (2) placed on bottom bed (5). Machine ram is move to upward direction slightly. Here the Small gap is obtained between hot formed dished end (Fig-9) and top portion of the forming die (2).
[0057] In this new method plurality of connecting hook (8) welded on top die (1) and forming die (2), now the set of connecting plates (7) are locked to the connecting hook (8) in opposite to one to another. New designed U plate (9) is insert between hot formed dished end (10) and top portion of the forming die (2).
[0058] After inserting the U plate (9) the machine ram is move to upward direction, here top die (1) and forming die (2) is connected with connection hook (8) and connecting plate (7).so while the ram is move upward direction top die (1) and forming die (2) is move upward direction along with U plate(9). The ram continuously move upward direction the U plate (9) is try to pull the dished end (10) from bullet (11).
[0059] The temperature approximately 900 ºC is available between inside the dished end (10) surface and bullet outer surface, due to heat dished end(10) not stuck with bullet, so while machine ram moving upward direction the U plate (9) pulling the dished end (10) and easily remove from bullet (11).
[0060] After removing the dished end (10) from the bullet (11), it is unloaded from machine by using crane.
[0061] Using this new arrangements (fig-11) human activities are reduced (ergonomics) while dished end (10) removal process. There is no cooling process (fig-4a) so dished end (10) not stuck with bullet (11).
[0062] Hence the present invention eliminate the separate setting and manual activities while removing dished ends (10) so the operator fatigue is reduced in this new method.
[0063] 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 within scope of the invention.
[0064] 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.
[0065] 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.
[0066] 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”.
[0067] 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.
[0068] 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.
[0069] 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.
[0070] 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.

Claims:WE CLAIM
1. A device for removal of boiler fitting dished end from bullet during hot pressing process on pressing machine comprising:
a base plate (13) welded with split ring used for bullet locating to the exact center to the machine bottom bed (5);
split ring (12) part a & part b for rigidly held the bullet while hot forming and removal process;
plurality of connecting hooks (8) to connect the top die (1) and forming (2) die while removal process;
a set of connecting plates (7) using to pull the forming die along with U plate while removal process;
a U plate (9) to pull the hot formed dished end from bullet while removal process.
2. The device for removal of boiler fitting dished end as claimed in claim 1, wherein forming bullet (11) bottom side square grove provision is available for bullet (11) handling purpose and the bullet (11) bottom portion is insert to the split ring.
3. The device for removal of boiler fitting dished end as claimed in claim 1, wherein bullet (11) locked with movable split ring and bullet (11) bottom portion rigidly clamped by split rings at exact center of machine.
4. The device for removal of boiler fitting dished end as claimed in claim 1, wherein pressing the bullet (11) is kept stationary at the bottom by rigid clamping of new base plate (13) and split ring arrangements.
5. The device for removal of boiler fitting dished end as claimed in claim 1, wherein the top die (1) and forming die (2) set the exact center of the machine top plate (4) by using bolt and nut.
6. The device for removal of boiler fitting dished end as claimed in claim 1, wherein forming die (2) is locked with top die (1) by using lock pin(3).
7. A method for removal of boiler fitting dished end from bullet during hot pressing process on pressing machine comprising:
fixing the new base plate (13) and lock the bullet using split rings (12) at exact center of the machine bottom bed (5);
setting the top die (1) and forming die (2) at top plate (4);
heating the dished end plank located on bullet then complete the hot forming pressing process;
releasing the lock pin (3) and separate the forming die (2) from top die (1); move the machine ram slightly upward direction where small gap is obtained bet ween hot formed dished end (10) and forming die (2);
attaching connecting plate (7) to the connecting hook (8) between top die (1) and forming die (2);
inserting the U plate (9) bet ween hot formed dished end (10) and forming die (2);
moving the machine ram in upward direction;
8. The method for removal of boiler fitting dished end as claimed in claim 7, wherein U plate (9) pull the hot formed dished end(10) and easily remove the dished end(10) from bullet(11) due to upward force of machine ram and using available heat between dished end(10) inner surface and bullet (11) outer surface.
9. The method for removal of boiler fitting dished end as claimed in claim 7, wherein the ram continuously move upward direction to pull the dished end (10) from bullet (11).