FORM 2
THE PATENTS ACT 1970 (39 of 1970)
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; rule 13)
TITLE OF THE INVENTION Rapid Pattern Making System
APPLICANTS
TATA MOTORS LIMITED,
an Indian company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
INVENTORS
Mandar Thite, Sachin Vedpathak
and Narendra Brahme
all are Indian Nationals
of TATA MOTORS LIMITED an Indian company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner in which it is performed.

FIELD OF INVENTION
The present invention is related to pattern making system and more particularly it relates to rapid pattern making system with non uniform staking selection and adhesive roller.
BACKGROUND OF THE INVENTION
Generally pattern making industries uses thermocole for pattern making. The said thermocole pattern making has typical pattern making steps. Said thermocole patterns are made in following steps
a) Study the design
b) Design the raw block
c) Raw block machining with different setup based on the design.
d) Built the pattern as per design
e) Final assembly of pattern
f) Inspection of pattern
The Final patterns made by above mentioned steps, are used for manufacturing of the casting pattern. The above conventional pattern making process is having some drawbacks and limitations such as CNC machining cost is high, Through put time in making pattern is approximately 4 Weeks for medium large type, the powder produced during the CNC machining of thermocole is hazardous, it is environmentally not safe, the waste powder produced during CNC machining of thermocole cannot be re-used, the undercut areas of pattern required to be hand touched, the raw block/splitting of block design is required to be made manually, more agencies are involved in pattern making process, like design / Programming, CNC shop, Pattern shop and inspection, manual work during final pattern making is must.

The present invention is developed to manufacture thermocole pattern with ease which eliminates the three dimensional computer numerical control (CNC) machining enabling the elimination of hazardous dust formed during 3D CNC machining. The present invention reduces the time taken for patterns making up to approx. 60% and the hand touchup activity is also reduced. The quality of finished pattern is better than pattern manufactured with the help of conventional process.
SUMMARY OF INVENTION
The present invention provides a rapid pattern making system comprising; at least one stacking centre (1) is adapted for staking of non uniform thickness of work to be machined/processed; at least one machining centre (2) provided for machining/cutting patterns from non uniform section; at least one conveyor mechanism (3) adapted for transporting said machined/cut non-uniform patterns, said conveyor mechanism including a conveyor belt configured for carrying machined/cut pattern, at least one adhesive roller for applying adhesive uniformly to bottom of said machined sheet and a gauge for accurate location of said machined sheets with reference to other sheets; an upright movement mechanism (4) being a final assembly table configured to move downward by a value equal to thickness of each machined sheet to maintain its height equivalent to the height of said conveyor mechanism (3) table.
The machining centre (2) is provided with CNC machine for two dimensional machining of non uniform thickness pattern. The upright movement mechanism (4) is actuated by either of electric motor or pneumatic or hydraulic cylinder. The upright movement mechanism (4) comprises a stopper/gauging column (4c), a adhesive roller activation switch (4a) and gauging plate (4b), the first sheet gets engaged in said gauging column after machining and presses the said adhesive roller activation switch which activates said adhesive roller (3b) for applying adhesive to bottom of said machined sheet.

The staking centre (1) stakes the sheets as per the input requirement of CNC program. The machining centre (2) selects sheet of required height from the said stacking centre (1) as per the input requirement of CNC program. The machining centre (2) having a cutting element (2a) which is hot wire with a diameter of at least 5 mm which follows a desired profile of cross section with the help of CNC program and runs offset to said profile by the value of radius said cutting element(2a). The gauging plate (4b) is adjustable provided for the gauging of various dimensions of sheets.
STATEMENT OF INVENTION
The present invention provides a rapid pattern making system comprising;
at least one stacking centre (1) is adapted for staking of non uniform thickness of work to be machined/processed;
at least one machining centre (2) provided for machining/cutting patterns from non uniform section;
at least one conveyor mechanism (3) adapted for transporting said machined/cut non-uniform patterns, said conveyor mechanism including a conveyor belt configured for carrying machined/cut pattern, at least one adhesive roller for applying adhesive uniformly to bottom of said machined sheet and a gauge for accurate location of said machined sheets with reference to other sheets; an upright movement mechanism (4) being a final assembly table configured to move downward by a value equal to thickness of each machined sheet to maintain its height equivalent to the height of said conveyor mechanism (3) table.
BRIEF DESCRIPTION OF DRAWINGS
Figure-01 which shows the isometric view of the rapid pattern making system ,
in accordance with the present invention. Figure-02 which shows isometric veiw of staking center (1) which stakes sheets
of different thickness. Figure-03 which shows the machining centre (2) provided for machining/cutting

patterns from non uniform section. Figure-04 which shows the conveyor mechanism (3) provided for transporting
machined/cut non-uniform patterns. Figure-05 shows the upright movement mechanism (4) or final assembly table.
BRIEF DESCRIPTION OF INVENTION
In accordance with the present invention, rapid pattern making system comprises; stacking centre 1 which stakes the non uniform thickness thermocole, machining centre 2 for making non uniform section of pattern, conveyor mechanism 3 with gauging for transporting said non uniform pattern made, upright movement mechanism 4 which finally assembles the non uniform thickness pattern to make final pattern.
Said stacking centre 1 having non uniform thickness thermocole to be fed to machining centre 2. Said machining centre 2 having CNC machine for machining two dimensional non uniform thickness thermocole. Said conveyor mechanism 3 having a conveyor belt for carrying machined thermocole, an adhesive roller for applying adhesive to the bottom of said machined thermocole sheet and gaug for accurate location of said machined thermocole sheets with each other. Said upright movement mechanism 4 is actuated by motor or pneumatic or hydraulic cylinder. Said mechanism 4 is a final assembly table wherein said table moves downwards by a value equal to thickness of each machined sheet to maintain its height equivalent to the height of said conveyor mechanism 3
The present invention is capable of manufacturing the thermocole pattern with ease and eliminates the three dimensional computer numerical control (CNC) machining enabling the elimination hazardous dust produced during 3D CNC machining. The time taken for patterns making is reduced approx. up to 60% and the hand touchup activity is also reduced. The quality of finished pattern is better than the pattern manufactured by a conventional pattern making process.

DETAILED DESCRIPTION OF INVENTION
In accordance with the present invention, rapid pattern making system comprises; stacking centre 1 which stakes the non uniform thickness thermocole, machining centre 2 for making non uniform section of pattern, conveyor mechanism 3 with gauging for transporting said non uniform pattern made, upright movement mechanism 4 which finally assembles the non uniform thickness pattern to make final pattern.
Said stacking centre 1 having non uniform thickness thermocole to be fed to machining centre 2. Said machining centre 2 having CNC machine for machining two dimensional non uniform thickness thermocole- Said conveyor mechanism 3 having a conveyor belt for carrying machined thermocole, an adhesive roller for applying adhesive to the bottom of said machined thermocole sheet and gauge for accurate location of said machined thermocole sheets with each other. Said upright movement mechanism 4 is actuated by motor or pneumatic or hydraulic cylinder. Said mechanism 4 is a final assembly table wherein said table moves downwards by a value equal to thickness of each machined sheet to maintain its height equivalent to the height of said conveyor mechanism 3
The said stacking centre 1 is having standard thermocole sheets la with different thickness stacked as per the input requirement of CNC program,
The said standard thermocole sheets with variable heights stacked according to the input given to the machining centre 2 by the programmer. The said machining centre 2 selects sheet of required height from the said stacking centre 1 having standard thermocole sheets with different thickness stacked as per the input requirement of CNC program..
Said machining centre 2 is having two dimensional CNC cutting machine which uses hot wire as a cutting element 2a for non uniform sectioning of said

thermocole. The said cutting element 2a cuts the said thermocole sheet as per CNC program input.
The said cutting element 2a is having 5mm diameter. The said thermocole sheets la is set on the machining centre with reference to the marked centerlines on the sheets or the edges of the said sheets. The said cutting element follows the profile of cross section with the help of CNC program. The said cutting element runs offset to the profile by the value of wire radius. The cutting element is selected as per the desired profile to be cut from the thermocole sheets.
The said conveyor mechanism 3 is having a conveyor belt 3 a for carrying machined thermocole, an adhesive roller 3b for applying adhesive to the bottom of said machined thermocole sheet and gauge 3c for accurate location of said machined thermocole sheets with each other.
The conveyor belt with the help of rollers carries said machined thermocole sheets to the said adhesive roller which then applies adhesive to the bottom of the said thermocole sheets. The said conveyor mechanism 3 having a gauge for correctly locating the said machined thermocole sheets with respect to each other.
The said conveyor mechanism 3 is having an adhesive roller which is in contact with thermocole sheet after execution of the machining of said thermocole sheets/second program. So the adhesive is not applied on the base /bottom of first thermocole sheet, and the activation switch for said adhesive roller is provided in said upright movement mechanism 4. The adjustable gauge plate's is for the gauging of thermocole sheets of various dimensions.
Said upright movement mechanism 4 is actuated by motor or pneumatic or hydraulic cylinder. Said mechanism 4 is a final assembly table wherein said table moves downwards by a value equal to thickness of each machined sheet to maintain its height equivalent to the height of said conveyor mechanism 3. Said upright movement mechanism 4 is a final assembly table to move the said table

downwards. Initially the said table is at the same height as the height of said conveyor mechanism 3. But during the entire process the said table moves downwards by a value equal to height of each machined thermocole sheets to maintain its height equivalent to the height of said conveyor mechanism table. The movement of said final assembly table can be motorized or by actuation through pneumatic or Hydraulic cylinder. The downward movement distance is decided based on the thickness of the machined thermocole sheet.
The said upright movement mechanism 4 having stopper cum gauging column 4c with a adhesive roller activation switch 4a and gauging plate 4b. After machining, the first thermocole sheet gets engaged in the gauging column and it presses the said adhesive roller activation switch which then activates said adhesive roller mechanism.
The present invention is capable of manufacturing the thermocole pattern with ease and eliminates the three dimensional computer numerical control (CNC) machining enabling the elimination hazardous dust produced during 3D CNC machining. The time taken for patterns making is reduced up to approx. 60% and the hand touchup activity is also reduced. The quality of finished pattern is better than the pattern manufactured by conventional pattern making process.
The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.

WE CLAIM
1. A rapid pattern making system comprising;
at least one stacking centre (1) is adapted for staking of non uniform thickness of work to be machined/processed;
at least one machining centre (2) provided for machining/cutting patterns from non uniform section;
at least one conveyor mechanism (3) adapted for transporting said machined/cut non-uniform patterns, said conveyor mechanism including a conveyor belt configured for carrying machined/cut pattern, at least one adhesive roller for applying adhesive uniformly to bottom of said machined sheet and a gauge for accurate location of said machined sheets with reference to other sheets; an upright movement mechanism (4) being a final assembly table configured to move downward by a value equal to thickness of each machined sheet to maintain its height equivalent to the height of said conveyor mechanism (3) table..
2. The system as claimed in claim 1, wherein said machining centre (2) is provided with CNC machine for two dimensional machining of non uniform thickness pattern,.
3. The system as claimed in claim 1, wherein said upright movement mechanism (4) is actuated by either of electric motor or pneumatic or hydraulic cylinder.
4. The system as claimed in claim 1, wherein said upright movement mechanism (4) comprises a stopper/gauging column (4c), a adhesive roller activation switch (4a) and gauging plate (4b), the first sheet gets engaged in said gauging column after machining and presses the said adhesive roller activation switch which activates said adhesive roller (3b) for applying adhesive to bottom of said machined sheet.
5. The system as claimed in claim 1, wherein said staking centre (1) stakes the sheets as per the input requirement of CNC program.

6. The system as claimed in claim 1, wherein said machining centre (2) selects sheet of required height from the said stacking centre (1) as per the input requirement of CNC program.
7. The system as claimed in claim 1, wherein said machining centre (2) having a cutting element (2a) which is hot wire with a diameter of at least 5 mm which follows a desired profile of cross section with the help of CNC program and runs offset to said profile by the value of radius said cutting element(2a).
8. The system as claimed in claim 1, wherein gauging plate (4b) is adjustable provided for the gauging of various dimensions of sheets.
9. The rapid pattern making system substantially as herein described with reference to the accompanying drawings.