FORM-2
THE PATENTS ACT, 1970
(39 OF 1970)
COMPLETE SPECIFICATION.
(Section 10; Rule 13)
Title: - New Advanced Featured double Colum Band saw Machine

Name , Nationality & Address of the Applicant


ITL INDUSTRIES LIMITED (Incorporated Company under Indian Company Act, 1956) 111, Sector -"B", Sanwer Road , Indore, 452015 (M.P.).lndia

The following specification particularly describes the nature of this invention and the manner in which it is performed:-
Title: - New Advanced Featured Double Colum Band Saw Machine .
Filed of the Invention:-
Present invention is new advanced featured double Colum band saw machine with linear motion guides on vertical columns of double column band saw machine, electronic feed regulation of cutting head by electronic sensor , four wheel construction cutting head for band saw machine above 1000 millimeter capacity., floating shuttle wise to adjust automatically while feeding the material stock into the cutting area & multi indexing of Bar in single stroke of shuttle which enhanced the productivity of the machine with easy process and reduced power & time .
Back Ground and Prior invention :-
High speed metal cutting band saw machines with twin column are in use for last 2 Vi decades using HSS bimetal band saw blades. These machines are having double column construction wherein the cutting head is guided in two vertical columns. The Cutting Head is provided with phosphorus branze bushes which slides on vertical columns which are hardened ground and hard chrome plated. HSS Bimetal Band Saw Blades perform very well, cut faster, taper free cuts when blade is stretched above 35000 PSI force to
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obtain very strong beam. When this force is applied on to the blade through Hydraulic Cylinder or manually by screw, it tends to distort the whole structure. Minor distortion affects the sliding of cutting head on the vertical columns, as such, some clearance is maintained between column and bush which compensate the distortion. Because of this clearance, cutting accuracies and blade life performance goes down. Also, many times, the cutting head bushes got jammed on the columns and does not come down at definite feed rate to cut the material. Jerking movement of cutting head affects blade life as well as many times breaks the blade due to sudden jerk, material cut on these Band Saw machines have varied hardness because of their composition and heat treatment. Many times due to improper heat treatment, post manufacturing process causes uneven hardness in the material. Band Saw Machines are operated through Hydraulic Cylinders for up down motion of the Cutting Arm. When cutting resistance of the material is more due to its property or the length of the cut does not allow blade to penetrate in the material and whereas the down feed remain constant at a definite feed rate. To avoid crooked cutting or failing of the blade, it is necessary to regulate the feed automatically to avoid poor cutting and damage to the blade. For this purpose, hydraulic sensors are provided to regulate the feed but sensing time is so long that by the time feed is regulated, the damage already takes place, as such, the machine user does not run the machine at optimum speed and feed loosing productivity. Band Saw Machines are being manufactured with two wheel construction on which blade rotates under pre set stretching face through Hydraulic Cylinder. One wheel is mounted on the gear box which acts as prime mover and other wheel is mounted on a pin which is fixed in a tension assembly being regulated by Hydraulic Cylinder. The two wheel construction works
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well up to 1000 millimeter cutting capacity where the wheel diameter is around 1500 millimeter and having weight of around 700 kgs. For larger model above 1000 millimeter capacity, wheel diameter becomes very large and heavy which requires huge space to accommodate. Also, it is very difficult to transport properly in assembled condition, as such, cost of installation and maintenance becomes very high. Also, it requires very long cutting blade leading to extra manpower to replace and very expensive. In fully automatic Band Saw Machine, cutting of straight rolled bars is convenient, but, it becomes very difficult to cut forged uneven surface bars, distorted rolled bars and cast bars because they strike with the fixed jaws of the machine causing damage to the machine and variation in cut length. As such, it is important to have some facility which can accommodate such bars and adjust vise while indexing to the cutting area. Conventional Automatic Band Saw Machines are designed on the shuttle system wherein after every Indexing, main vise clamps the bar, shuttle vis^ opens & return to the set cut length position and clamps the bar again. After cutting of the bar, main vise opens and shuttle vise index the b&r to pre set length and again comes back to its home position. In this construction, lot of time is wasted in frequent opening, closing and indexing of the shuttle. Also, the length variation is more in cut pieces.
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Description of invention :-
Present claimed invention :-
To overcome limitation of distortion in the cutting head and to avoid jerky down movement of cutting head due to friction between vertical columns and bush of the cutting head , innovation has been carried by using linear motion guide bearing for both the vertical columns which offers very smooth and jerk free movement of the Cutting Head while cutting. This arrangement allows blade stretching up to 35000 PSI to obtain very strong beam of cutting blade to keep taper free cuts and increased tool life. LMG maintenance is very easy and can be replaced at site without any difficulty and loss of time. Also, it is very easy to maintain as lubrication can be done automatically on continuous basis. Solid forged hardened ground chrome plated vertical columns have been replaced by the square pipes which offers high rigidity to absorb stretching force and bring down over all cost of equipments and make it echo friendly as it does not require heat treatment as well hazardous hard chrome plating process. Electronic sensor figure -2, ( 3 ), these Sensors are very sensitive and acts very fast to regulate the cutting feed which improves cutting and avoid blade breakage in case of any irregularity in the material or excessive feed is sensed due to cutting resistance of the material at a particular point. The sensors have been designed in such a way that slightest uplift of the cutting head which rests on spring suspension is noticed and after an allowable limit, it sends signal to the hydraulic circuit to stop the oil flow from the cylinder till the cutting head comes to its position and again signal is given to restart the hydraulic supply/discharge from the hydraulic power pack by operating hydraulic
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solenoid valve. Four wheel arrangement figure -1 , (2) to overcome the problem of huge space limitation, four wheel construction of cutting head makes it small due to small wheel diameters positioned at two numbers each side. By using four wheels, the blade length is reduced as well as the over all weight of the cutting head reduced substantially. In this construction, drive side wheel is mounted on the gear box and tension side wheel is mounted on hydraulic tension arrangement. One wheel above drive side wheel is mounted at definite position through a mounting arrangement. Similarly, one wheel above the tension side , is provided. Such construction makes it very easy to use huge capacity of the machine. Floating shuttle arrangements figure -2, (5) to accommodate forged, uneven surface bars, distorted bars etc. with their rough surface, can easily be fed into the cutting area with the provision of Floating Shuttle vise Arrangement. The construction of floating vise has been designed in a such a way that the whole shuttle table shifts to the either side of the indexing axis to adjust in such a way that the bar does not rub on the fixed jaws of main vise. Thus cut pieces can be obtained without length variation. Multi Indexing without frequent opening of shuttle wise figure -2 , (6) PLC program and shuttle stroke has been designed in such a way that small cut lengths can be obtained at a higher production rate without return stroke of the shuttle up to the cut length distance after every cut. In such construction, depending upon the programmed cut length, the shuttle moves forward and stops after indexing the set length of the material. When the material is cut, again shuttle moves forward to set length distance and piece is cut, this way several pieces are cut. This operation is continuously done till the shuttle reaches to main vise, from this point, shuttle vise comes home position
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We Claim,
1. Linear Motion Guides on Vertical Columns of Double Column Band Saw
Machine .
2. Electronic feed regulation of Cutting Head by electronic sensor.
3. Four wheel construction Cutting Head for Band Saw Machine above 1000 millimeter capacity.
4. Floating shuttle wise to adjust automatically while feeding the material stock into the cutting area.
5. Multi Indexing of Bar in Single Stroke of Shuttle.
Dated this 29th day of May 2009

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