DESC:FIELD OF THE INVENTION:
This invention relates to the field of electro-mechanical engineering. Particularly, this invention relates to reutilization of free energy into other alternative sources of energy in forging presses.

BACKGROUND AND INTRODUCTION:
Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.
In the operation of a forging press, the utilization of energy from the motor is a crucial aspect. The motor channels its energy to initiate the rotational motion of the flywheel, a key component in this mechanical system. This rotational force is then ingeniously transformed into a reciprocating motion through the implementation of an eccentric crankshaft. This conversion mechanism is pivotal, as it facilitates the translation of the circular movement of the flywheel into a back-and-forth motion. The eccentric crankshaft, by virtue of its design, imparts a distinct and controlled linear motion to the RAM. Consequently, the linear movement of the RAM becomes the driving force behind the forging press, enabling it to efficiently perform the forging process with precision and power. The intricate interplay of these components underscores the engineering ingenuity employed to harness and convert energy, ensuring the seamless and effective functioning of the forging press in shaping raw materials into desired forms.
Despite the integral role of the motor in initiating the rotational motion of the flywheel within the forging press, a noteworthy observation has been made that a significant amount of energy is lost between the motor and the flywheel since the entire energy from the motor is not fully used for running the flywheel. The inefficiency in the transfer of energy becomes evident in the form of excess energy that remains unutilized in the process. This surplus energy, which could potentially contribute to additional productive work, ends up being dissipated and wasted. The discrepancy between the energy input from the motor and the actual useful output in terms of the rotational motion of the flywheel highlights an area for potential improvement in the design and engineering of the forging press.
Accordingly, it is envisaged to develop a method and a system that utilizes excess energy for useful application.

OBJECTS OF THE INVENTION:
Owing to the current drawbacks of harnessing the power, a novel method is developed and used to reutilize the free rotational energy of the motor into useful energy.

It is another object of the present invention to provide a system that reutilizes the excess energy from the prime mover to useful energy which would be beneficial for powering the movement of the motors of different electrical appliances.

SUMMARY OF THE INVENTION:
According to this invention, there is provided a system for reutilization of free energy into other alternative sources of energy in forging presses, said system comprising:
- a prime mover;
- a flywheel, connected to said prime mover, by way of coupling means, such that as soon as said prime mover reaches its synchronous speed, power from said prime mover starts transferring to said flywheel through said coupling means;
- an alternator connected to said coupling means in order to receive power from said flywheel via said coupling means, said alternator being configured to generate power output;
- a servo-stabiliser configured to be coupled to said alternator in order to stabilize fluctuations in voltages of output of said alternator in order to provide constant voltage outputs; and
- an auto-changeover switch configured to, selectively, supply power to DB panel from a main grid power supply source, in case of a power outage from said alternator.

In at least an embodiment, said prime mover being an electric motor.

In at least an embodiment, said flywheel, connected to said prime mover, by way of V-belts, such that as soon as said prime mover reached its synchronous speed, power from said prime mover starts transferring to said flywheel through said V-belts.

In at least an embodiment, said alternator configured to be connected to said V-belt in order to receive power from said flywheel via said V-belt, said alternator being configured to generate power output.

In at least an embodiment, said V-belts which are stationed on grooves of the flywheel and being connected to a C-section pulley of said alternator; thereby, transferring power to the said alternator.
In at least an embodiment, said flywheel and prime mover being connected by way of a plurality of V-belts.

In at least an embodiment, said flywheel and alternator being connected by way of a plurality of V-belts.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:
The invention will now be described in relation to the accompanying drawings, in which:

Fig 1 illustrates block diagram system and its workflow, in accordance with an embodiment of the present disclosure; and
Fig 2 illustrates a schematic view of the system, in accordance with an embodiment of the present disclosure

DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS:
According to this invention, there is provided a system for reutilization of free energy into other alternative sources of energy in forging presses.

The major problem solved by this invention is minimization of extra electric cost incurred for running the motors of conveyors and man-coolers as well as press lights and bulbs; which, thereby leads to an increase in unit consumption of electricity.

The system (100) and its workflow are illustrated in Figure 1, wherein the components are denoted by the following numerals:
101: Forging press;
102: Prime mover (motor);
104: Flywheel;
106: Alternator;
108: Stabilizer;
109: coupling mechanism (V-belt);
110: Auto-change over switch;
112: main grid power supply source;
114: DB panel; and
116: Output.

Fig 2 illustrates a schematic view of the system, in accordance with an embodiment of the present disclosure.

In one embodiment, the present invention provides a system comprising a main motor (102), a flywheel (104), an alternator (106), a servo-stabilizer (108), a coupling mechanism (preferably, a V-belt) (109), heavy duty automatic switch (110), and distribution board panel (114).

In at least an embodiment, the main motor (102) is an electric motor which is a machine that converts electrical energy into mechanical energy. Motors operate through interaction between motor’s magnetic field and electric current in a wire winding to generate the torque which is applied on a shaft.

In at least an embodiment, the motor (102) is coupled to the flywheel (104) which is a heavy wheel attached to a rotating shaft to smoothen the delivery of power from the motor (102) to the machine. The inertia of the flywheel (104) opposes and moderates fluctuations in speed and stores energy for intermittent use.

In forging presses (101), power is transferred from the motor (102) to the flywheel (104) which in turn rotates an eccentric shaft and RAM movement, leading to forging operation. At the time of press operation, most of the energy is provided by the flywheel (104).

In at least an embodiment, an alternator (106) and the flywheel (104) are interconnected with each other with the help of coupling mechanism (109), thus transferring power from the flywheel (104) to the alternator (106).

Connecting a motor (102) and flywheel (104), in a forging press (101), can be achieved through various methods, including direct coupling with keyed shafts or splines, a belt and pulley system for adjustable speed ratios, a chain drive for heavy-duty applications, gear transmission for precise control, the integration of a clutch mechanism for frequent start-stop scenarios, flexible couplings to compensate for misalignment, hydraulic couplings for smoother engagement, and torsion shafts to absorb torque and reduce vibration. The choice of method depends on factors such as power requirements, speed control, torque transmission, shock absorption, and maintenance considerations, ensuring that the selected approach meets the specific needs of the forging press application while adhering to safety standards and allowing for regular maintenance for reliability.

An alternator is an electrical generator which converts mechanical energy into electrical energy in the form of an alternating current.

However, owing to voltage fluctuations that occur in the operation, in at least an embodiment, a stabilizer (108) is added in the system which results in constant voltage output. This constant voltage is used to, then, power equipment such as conveyors, man-coolers, electric light bulbs, and tubes on a shop floor. The servo-stabilizer (108) is an electrical device that is used to provide a stable voltage output to a load at its output terminals irrespective of any variations in the input i.e. input supply.

In at least an embodiment, a heavy-duty automatic switch (110) is an auto-change over switch which is used to automatically transfer electricity from a commercial power grid to a local generator when a power outage occurs.

In one embodiment, the workflow of the components occurs in the following steps:
A. A power is supplied to a prime mover (102) which results into running of the prime mover (102).
B. As soon as the prime mover (102) reaches its synchronous speed, transferring of power takes place to the flywheel (104) with the help of coupling mechanism (109).
C. The coupling mechanism (preferably, V-belts) (109) which are stationed on grooves of the flywheel (104) are connected to the C-section pulley of the alternator (106), thus transferring the power to the alternator (106).
D. This leads to generation of sufficient voltage in the device. However, owing to the fluctuations in the voltage which might occur during running, stabilizers (108) are incorporated in the setup which helps in maintaining constant voltage output.
E. Furthermore, auto change over switches (110) are used wherein the electricity from the main grid power supply (112) is used for supplying the electricity to DB panel (114), in case of a power outage from alternator (106), if any.

The illustrative system according to the present invention is found to save a minimum of 90 to 600 units in a time period of 5 to 15 days.

According to a non-limiting exemplary embodiment, the following relationship between RPM of flywheel, RPM of alternator, and electricity units generated was observed:
RPM of flywheel: 96
RPM of alternator: 1586 – 1610
Unit generated: 1 unit of electricity
RPM of flywheel : RPM of alternator : electricity units generated = 528 : 8726 to 8855 : 1

The above descriptions are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the scope of the present invention.

Throughout this specification the word “comprises”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

While considerable emphasis has been placed herein on the particular features of this disclosure, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other modifications in the nature of the disclosure or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

,CLAIMS:WE CLAIM,

1. A system for reutilization of free energy into other alternative sources of energy in forging presses (101), said system comprising:
- a prime mover (102);
- a flywheel (104), connected to said prime mover (102), by way of coupling means (109), such that as soon as said prime mover (102) reaches its synchronous speed, power from said prime mover (102) starts transferring to said flywheel (104) through said coupling means;
- an alternator (106) connected to said coupling means in order to receive power from said flywheel (104) via said coupling means, said alternator (106) being configured to generate power output (116);
- a servo-stabiliser (108) configured to be coupled to said alternator (106) in order to stabilize fluctuations in voltages of output of said alternator (106) in order to provide constant voltage outputs; and
- an auto-changeover switch (110) configured to, selectively, supply power to DB panel (114) from a main grid power supply source (112), in case of a power outage from said alternator (106)

2. The system as claimed in claim 1 wherein, said prime mover (102) being an electric motor.

3. The system as claimed in claim 1 wherein, said flywheel (104), connected to said prime mover (102), by way of V-belts (109), such that as soon as said prime mover (102) reached its synchronous speed, power from said prime mover (102) starts transferring to said flywheel (104) through said V-belts.

4. The system as claimed in claim 1 wherein, said alternator (106) configured to be connected to said V-belt in order to receive power from said flywheel (104) via said V-belt, said alternator (106) being configured to generate power output (116).

5. The system as claimed in claim 1 wherein, said V-belts which are stationed on grooves of the flywheel (104) and being connected to a C-section pulley of said alternator (106); thereby, transferring power to the said alternator (106).

6. The system as claimed in claim 1 wherein, said flywheel (104) and prime mover (102) being connected by way of a plurality of V-belts.

7. The system as claimed in claim 1 wherein, said flywheel (104) and alternator (106) being connected by way of a plurality of V-belts.

Dated, this 31st day of December, 2023

CHIRAG TANNA
of NOVO IP
APPLICANT’s PATENT AGENT
REGN. NO. IN/PA – 1785