Claims:WE CLAIM

1. An apparatus to perform automatic Submerged Arc Welding of I-beam using variable speed traveling gantry mechanism comprising of vertical screw rod (3) and Linear Motion bearing (2) mounted on a mounting plate (1), a bearing (10) is placed on the Linear Motion guide (2) for mounting horizontal screw rod assembly (4), wherein welding head comprises of Submerged Arc Welding welding torch (6) and wire feed motor (5) mounted by the Linear Motion guide bearing (2) on the mounting plate (1).

2. The apparatus to perform automatic Submerged Arc Welding of I-beam as claimed in claim 1, wherein the vertical screw rod (3) and the Linear Motion bearing (2) are mounted on the mounting plate (1) by multiple Allen screws (11), end support plate (9) and lock plate (8).

3. The apparatus to perform automatic Submerged Arc Welding of I-beam as claimed in claim 1 or 2, wherein the torch assembly (5,6) is held with the help of multitude of Allen screws to the horizontal screw rod (4) which is in turn mounted on the Linear Motion guide (2) by Linear Motion bearings (10), in which the Linear Motion guide (2) is fixed by Allen screws (11) on the mounting plate (1) which in turn is assembled on the vertical screw rod (3) by end support plate (9) and the lock plate (8).

4. The apparatus to perform automatic Submerged Arc Welding of I-beam as claimed in claims 1-3, wherein the vertical screw rod (3) is actuated using a handle (7).

5. The apparatus to perform automatic Submerged Arc Welding of I-beam as claimed in claims 1-4, wherein the height of the welding torch is adjusted with the help of vertical screw and the horizontal movement by horizontal screw.

6. The apparatus to perform automatic Submerged Arc Welding of I-beam as claimed in claims 1-5, wherein the welding head assembly is fixed to the gantry mechanism (12) using a channel (17), I-beam (13) is placed on a supporting fixture (14) in an inclined position including 45 degrees, in which the gantry mechanism (12) travels on guide rails (16) driven by geared motor (15).

7. The apparatus to perform automatic Submerged Arc Welding of I-beam as claimed in claim 6, wherein the speed of the gantry (12) is controlled by a variable frequency drive (18), in which controls are provided on a pendant (19) attached to the gantry mechanism (12) and power supply cable (21) to the welding power source (22) is arranged through a cable drag chain (20) which travels along with the gantry mechanism (12) throughout the length of the machine.

8. The apparatus to perform automatic Submerged Arc Welding of I-beam as claimed in claims 1-7, wherein the Linear Motion bearing (2) serves as a guide for smooth vertical movement of the welding torch assembly, and the vertical screw rod (3) and horizontal screw rod (4) serves as the drive for vertical and horizontal movement of the welding torch respectively.
, Description:“APPARATUS TO PERFORM AUTOMATIC SUBMERGED ARC WELDING OF I-BEAM USING VARIABLE SPEED TRAVELING GANTRY MECHANISM”

FIELD OF INVENTION :
[001] The invention relates to the manufacturing of the structural members of the steam generators. Particularly, this invention relates to an apparatus to perform automatic Submerged Arc Welding of I-beam using variable speed traveling gantry mechanism.
[002] This invention utilizes a SAW welding apparatus for automatic welding of the structural beams with the help of a gantry mechanism for travelling through the length of the beam, thereby reducing the welding defects such as porosity, slag inclusions, slip etc.

BACKGROUND OF THE INVENTION/PRIOR ART :
[003] 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.

[004] Structural members constitute about 50% of the boiler weight in a standard 800MW boiler. Since it is the main load carrying member in the boiler, the structural members are usually engineered and fabricated. This usually comprises of two flanges (top & bottom) interconnected using a web, which are flat products of specified dimensions.

[005] Fabrication of structural beams has become necessary whenever sizes other the normally available rolled products are needed. If the welding is done manually then the time taken for completion and rework is very high which affects the productivity.

[006] Thus, manually welded structural members results in a long cycle time and also prone to defects and reworks. Very long sizes of the beams that are usually needed makes good manual welding practically unviable. For the reduction of the defect rate and rework, an automatic method for welding with high metal deposition rate is required.

[007] In view of the above, the present invention introduces a low cost and highly energy efficient submerged arc welding (SAW) of the structural beams.

OBJECTS OF THE INVENTION :
[008] An objective of the invention is to provide an apparatus to perform automatic Submerged Arc Welding of I-beam (for welding of the flanges and web of the structural beams) using variable speed traveling gantry mechanism.

[009] Another objective of this invention is to reduce the welding duration of the beams by employing faster process rates.

[0010] Yet another objective of this invention is to make the system widely applicable, wherein the machine adjusts to the bead requirement, and faster and slower travel speed of the gantry mechanism are enabled.

[0011] Yet another objective of the invention is to provide an apparatus to perform automatic Submerged Arc Welding of I-beam using variable speed traveling gantry mechanism, which enables to minimize the manpower (welder) requirement for fabrication of beams from 15 man-days to 03 man-days.

[0012] Yet further objective of the invention is to effectively eliminate the welding defects arising due to the manual welding operation.

[0013] 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 :
[0014] 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.

[0015] This invention exploits the method of travelling gantry mechanism to achieve a continuous welding process for structural fabrication using a SAW welding head. The welding head comprises of SAW welding torch and wire feed motor mounted with the help of Linear Motion (LM) guide bearing on a mounting plate. The height of the welding torch can be adjusted with the help of vertical screw and the horizontal movement with the help of horizontal screw. The mounting plate is used to maintain the rigidity. LM guide bearing is used for smooth vertical movement. Also, vertical screw rod is provided so as to accommodate any beam size such as from 500 mm to 3000 mm width. The gantry mechanism travels on a guide rail with the help of geared motor drive. The speed of the gantry mechanism is regulated with a variable frequency drive mechanism as the speed of the gantry is dependent on the welding bead requirement. The power supply cable to the welding power source is arranged through a cable drag chain which travels along with the gantry mechanism throughout the length of the machine. All the carriage movement controls are provided on a pendant attached to the gantry mechanism. This gives the operator full control of the automatic mechanism for start and stop of the welding process.

[0016] 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.

[0017] 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.

[0018] 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 :
[0019] 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:-

Fig 1 shows: the individual components of the welding head assembly of the invention.
Fig 2 shows: the exploded view of the welding head assembly according to the invention.
Fig 3 shows: the assembled view of the welding head assembly in accordance with the invention.
Fig 4 shows: the final machine assembly of the automatic mechanism for structural welding of the present invention.

[0020] 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 OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS :

[0021] 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.

[0022] The present invention makes a disclosure regarding a technology pertaining to an apparatus to perform automatic Submerged Arc Welding of I-beam using variable speed traveling gantry mechanism.

[0023] Now, reference may be made to Fig 1 illustrating the individual components of the welding head assembly of the invention. The mounting plate (1) is the part which holds all the components of the welding head assembly. The Linear Motion bearing (2) serves as a guide for smooth vertical movement of the welding torch assembly. The vertical screw rod (3) and horizontal screw rod (4) serves as the drive for vertical and horizontal movement of the welding torch. The geared motor (5) and SAW welding torch (6) are the welding components that feed the welding wire and carry out the welding.

[0024] Fig 2 illustrates the exploded view of the welding head assembly. The vertical screw rod (3) and the Linear Motion bearing (2) are mounted on the mounting plate (1) with the help of allen screws (11), end support plate (9) and the lock plate (8). The vertical screw rod (3) is manually actuated using the handle (7). Further, the bearing (10) is mounted on the Linear Motion guide (2) for mounting the horizontal screw rod assembly (4). Thereafter, the wire feed motor (5) and the SAW welding torch (6) are assembled as shown in the fig 3 in the assembled view of the welding head assembly.

[0025] The torch assembly (5, 6) is held rigidly with the help of multitude of Allen screws to the horizontal screw rod (4) which is in turn mounted on the LM guide (2) with the help of LM bearings (10). The LM guide (2) is fixed with the help of Allen screws (11) on the mounting plate (1) which in turn is assembled on the vertical screw rod (3) with the help of end support plate (9) and the lock plate (8).

[0026] Referring to Fig 4 indicating the total welding machine assembly after final fitting. The welding head assembly is fixed to the gantry mechanism (12) using a channel (17). The I-beam (13) is placed on the supporting fixture (14) in an inclined position of for example 45 degrees. The gantry mechanism (12) travels on the guide rails (16) driven by geared motor (15). The speed of the gantry (12) is controlled with the help of a variable frequency drive (18). For higher material deposition the speed of the gantry is lowered and vice versa. The gantry mechanism (12) travels along the length of the beam.

[0027] Also, all the controls are provided on a pendant (19) attached to the gantry mechanism and the power supply cable (21) to the welding power source (22) is arranged through a cable drag chain (20) which travels along with the gantry mechanism throughout the length of the machine.

Advantageous Features :
- Reduces the welding duration of the beams by employing faster process rates;
- Renders the system widely applicable, wherein the machine adjusts to the bead requirement;
- Enables Faster and slower travel speed of the gantry mechanism;
- Enables to minimize the manpower (welder) requirement for fabrication of beams from 15 man-days to 03 man-days;
- To effectively eliminate the welding defects arising due to the manual welding operation.

Working of the Invention :
[0028] The I beam (13) is placed on a fixture (14) in an inclined position of 45 degrees. The welding head as shown in fig 3 is used to feed the welding wire from the spool to the welding torch (6). The welding current and the voltage is main set in the power source (22). The after the gantry (12) is moved on the guide rail (16) with the help of geared motor (15). As the gantry (12) travels along the length of the beam (13) the welding torch (6) welds the joints of the flange and web of the I beam (13). The speed of the gantry (12) is regulated according to the weld bead requirement with the help of variable frequency drive (18).

Test Result :
The test results are as follows:
1. High production rate of the I beams is achieved
2. Quality of weld is improved.
3. Reduction of rework due to elimination of defects is achieved.
4. Less manpower required (reduced from 15 man-days to 03 man-days)
5. Smokeless welding process is established
6. Safety to the welder and welder satisfaction is achieved

[0029] 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.

[0030] 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.

[0031] 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 analogue 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”.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] 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.