‘SET-UP AND METHOD FOR GRINDING EXCESS WELD OF BUTT WELDING JOINTS OF WATER WALL PANEL TUBES’

FIELD OF INVENTION :
[001] The invention is directed to a Set-up and method for grinding excess weld areas of butt welding joints of water wall panel tubes.
[002] The present invention generally relates to water wall panel fabrication for high pressure boilers. The present invention more particularly relates to panel formation. Still more particularly the present invention relates to the grinding of straight tube butt joints of tubes. The invention further relates to elimination of involvement of more man powers for doing manual grinding of joints. It also eliminates environment pollution by restricting the grinding dust not to fly in air and collected in a bin box. The new method thereby eliminates manpower, material wastage, also reduces the cycle time and 100% ensures the quality as well as the finishing of grinding of butt joints to reduce reworks in panel formation.

BACKGROUND OF INVENTION :
[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] In water wall panels, the panels formation operation begins with the grinding of the butt joint grinding operation. A boiler comprises of water wall panels(Fig-1) which are the major part to carry steam and water. The tubes(Fig-2) used for panels of size Outer Diameter (OD) 38.1, 44.0, 51.8, 63.5mm are used with thickness ranging from 5.6 mm to 10.67 mm. The high chromium alloy tubes are termed as SA213T-12, SA213T-22, and SA213-T23 as per ASME standards. The length of the tubes as per design requirement varies from 10meters to 24 meters for different projects. The tubes received from store is varied from 10meters to 12 meters. To manufacture the required length of the tubes as per the design, for example if for a project the required tube length is 17 meters and supplied tube is 10 meters, then the 10 meters tube js to be cut to 7 meters. The two tubes(Fig-2) of 10 meters(A/Fig-2) and 7 meters(B/Fig-2) is to be chamfered and welded by straight tube butt welding machine and radiographic test is carried out for the joints. If the joint(C/Fig-2) is OK in radiographic test, then the tubes are fed to panel processing machine for panel formation process. Due to the welding at the joints, the extra weldment(C/Fig-2) is formed. The extra weldment has more diameter compared to the parent material. When the tube is fed to panel processing machine, it is not possible to weld the tube in panel processing machine as the gap between the rollers is exactly the outer diameter of the tubes. so, the existing practice is to grind the extra weldment(C/Fig-2) exactly up to the diameter of the parent tube. For grinding the extra weldment, the usual practice is to allot a contract labour, First of all, the tubes to be grinded is loaded on the bed. The contract labour is to fix the grinding machine and manually grinding is to be started. While grinding extra man power is provided to rotate the tube. After grinding, the surface at the butt joint area should be smooth and have exactly same diameter of the parent tube.

[005] Due to the existing method of grinding, it is done through manually by holding the grinding machine in hand by the contract employee which leads to manual fatigue. Number of joints grinding per shift is very less so that the panel processing machine is idle most of the time due to want of load. Due to manual grinding the dust flies in air and leads to air pollution. Due to covid-19 situation, there was restriction of contract employee, it was very difficult to do grinding of butt joints.
[006] The inherent limitations of the present method of doing manual grinding process by the conventional method are as follows:
Pollution was more due to grinding wheel particles.
After grinding, if the surface is smooth then the tube is fed to panel processing machine, otherwise once more grinding is to be done. This operation leads to rework cost more to organization.
Machine is idle most of the time due to want of load.
[007] Grinding is done through contract employee. Maximum 80 tubes can be grinded per day by the employee. There is 5 panel processing machine in Bldg-50 area. The requirement of total tubes to run the machine is 160 tubes per day. SO, most of the time the machines are idle due to want of load. Hence, Productivity decreases.
Grinding quality is not good.
[008] If the grinding is not smooth as per diameter of the tube, then there is chance of damage to machine parts. So, the machine will be idle. Quality wise the grinding is not satisfactory. Due to the ununiformed grinding, the quality of the welding is also not good at the butt joint area.
Health hazards.
[009] In the conventional method of grinding, the grinding particles are spilled on the floor and fine particles are mixed with air. As the particles are iron, if anybody inhales, it is very dangerous.
[0010] Unsafe working environment.
[0011] There is chance of slippage of contract employees while grinding as the grinding person is sitting on the round tubes.
More manpower required
[0012] For doing grinding in conventional method, one contract employee is for grinding and two employees for rolling the tubes.
Productivity reduced for panel processing machine.
[0013] As the machine is idle due to want of load, panels cannot be formed within the stipulated time. If panels are not formed in time, then it was difficult to hand over the finished product to site. So, directly productivity reduced.
Fatigue to employees.
[0014] If requirement is there to do grinding more tubes, then the contract employee is doing grinding beyond its capacity. This leads fatigue to employees.
More cost to organization.

[0015] In conventional method, for grinding of 50 tubes it requires minimum 10 grinding wheels. The cost to company is more. Another contract employee is required for cleaning the grinding wheels' particle on the floor, the cost to company on the basis of man powers is more.
[0016] The Tube grinding if not proper then the pitch will vary in this area and that will result in breakage of the fin guide unit.
[0017] So this process had found that it is time consuming and increases the utilization of materials as well as manpower also chances for poor quality of Butt joints.
[0018] In view of the above, the present invention has been introduced which can address the aforesaid shortcomings.

OBJECTS OF THE INVENTION :
[0019] The principal objective of this invention is to provide a set-up and a method for grinding of straight tube butt joint which overcomes disadvantages of prior art(s).
[0020] Another object of this invention is to provide a set-up and a method for grinding of straight tube butt joint which is simple in construction.
[0021] Still another object of this invention is to provide a set-up and a method for grinding of straight tube butt joint which involves automatic operation.
[0022] Yet another object of this invention is to provide a set-up and a method for grinding of straight tube butt joint which involves no chance of any reworks and no scope of any air pollution.
[0023] A further object of this invention is to provide a set-up and a method for grinding of straight tube butt joint which requires less man power.
[0024] Still further object of this invention is to provide a set-up and a method for grinding of straight tube butt joint which avoids slippage thereby ensuring safety.
[0025] Still another object of this invention is to provide a set-up and a method for grinding of straight tube butt joint which results in less time consumption.
[0026] Still further object of this invention is to provide a set-up and a method for grinding of straight tube butt joint which leads to reduction in fatigue to manpower.
[0027] Yet further object of this invention is to provide a set-up and a method for grinding of straight tube butt joint which improves in quality of finishing job.
[0028] 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 :
[0029] One or more drawbacks of conventional systems and process are overcome, and additional advantages are provided through the apparatus and a method as claimed in the present disclosure.
[0030] 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.
[0031] According to this invention, there is provided a Set-up for grinding of butt welding joint area comprising a fixture having bed, height adjustment mechanism, cross movement mechanism, Linear movement mechanism, grinding mechanism, tube loading with pinch roller mechanism, tube rotation mechanism and dust collector unit.
[0032] The bed includes multiple tubes, I-Beams and a baseplate. All the above said items are connected to each other through welding. The height of the bed is maintained approximately 650mm at the top of the tube. A screw jack is placed above the base plate which is for the purpose of height adjustment of for example 240mm.The base of the screw jack is tack welded with the base plate.
[0033] On the top of the multiple tubes, a setup of tubes and base plate is placed so that the top individual tubes can be moved freely in the bottom tubes when the screw jack is rotated.
[0034] On the top of the base plate, a cross movement mechanism is welded. So that the grinding mechanism can be moved across to give feed at the grinding zone.
[0035] Above the cross movement mechanism Linear movement mechanism is placed to give the linear movement to the grinding mechanism.
[0036] The grinding holding mechanism is welded above the Linear movement mechanism, the purpose of the grinding mechanism is to hold tightly the grinding machine.
[0037] A method for grinding of butt joint welding areas of tubes of water wall panels for high pressure boilers comprising steps of: -
- Tube to be grinded are loaded on the stand.
- The tube which is to be grinded is just rotated from the stand and is automatically placed on the pinch roller by gravity,
- Tubes to be grinded is placed on the bed of the grinding mechanism.
- The end of the tube is held in the 3 jaw chuck.
- The grinding wheel is placed against the grinding area by the LM guide mechanism.
- The grinding machine and the 3 jaw chuck is connected with compressed air through different air lines.
- Once all the setting is ok, the air valve is opened and grinding is started.
- The tube is rotated slowly through the 3 jaw chuck automatically and the feed is also given for grinding manually by rotating the handle through the cross movement mechanism.
- The dust is automatically collected in the dust collector which is placed just below the grinding area.
- Once the grinding is completed, the tube is rotated in the nearby dump.
- To do grinding another tube above said same process is continued.
- The set up for grinding grinds the tubes smoothly without any rework.
- It reduces the air pollution by providing safety cap over the grinding wheel so that the grinding dust after hitting the safety cap is directed into the dust collector unit.
- It reduces the Cycle time by reducing the setting time.
- It increases the efficiency by increasing the number of tubes grinding per shift.
- It reduces the man power fatigue while doing grinding and also Cost to company is reduced by reducing the engagement of more manpower.
- Instead of 3 manpower, 1 manpower can do grinding of tubes easily.

[0038] The inventive features/steps have been indicated in the principal claims and subsidiary features have been mentioned in the dependent claims.

[0039] 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.

[0040] 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.

[0041] 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 :
[0042] 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: -
[0043] Fig.1 - Shows the formed water wall panels.
[0044] Fig.2 - Shows the tubes and the butt joint welding area which is to be grinded before panel formation.
[0045] Fig.3 - Shows the complete fixture including bed and height adjustment mechanism in accordance with present invention.
[0046] Fig.4 - Shows the bed on which the other set up is established according to the invention.
[0047] Fig.5 - Shows the height adjustment mechanism/means of the invention.
[0048] Fig.6 - Shows the cross movement mechanism/means of the invention.
[0049] Fig.7 - Shows the linear movement mechanism/means of the invention.
[0050] Fig.8 - Shows the grinding mechanism/means of the invention.
[0051] Fig.9 -Shows the tube roller with pinch roller mechanism/means of the invention. Fig.10 - Shows the tube rotation mechanism/means of the invention.
[0052] Fig.11 - Shows the dust collector unit of the invention.
[0053] Fig.12 - shows set-up for grinding butt joint welding area of the tubes [1] according to the instant invention.

[0054] 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.

DETAIL DESCRIPTION OF THE PRESENT INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS OF PREFERRED EMBODIMENTS
[0055] 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 and alternative falling within the scope of the disclosure.
[0056] The present invention is pertinent to a technology regarding a set-up and a method for grinding of straight tube butt joint areas before panel formation for high pressure boilers. Now, reference may be made to Fjg.12 depicting set-up for grinding butt joint welding area of the tubes [1] according to the instant invention.
[0057] The entire grinding system comprises of bed [100,Fig-4], height adjustment mechanism [200,Fig-5], cross movement mechanism [300,Fig-6], Linear movement mechanism [400,Fig-7], grinding mechanism [500,Fig-8], tube loading with pinch roller mechanism [600,Fig-9], tube rotation mechanism [700,Fig-10] and dust collector unit [800,Fig-11]. The same is described herein below one by one.

Bed (100, Fig-4)
[0058] The bed [100] is fabricated by at least two I-Beams [4A], one base plate [4B] and four tubes [4C]. The two I-beams [4A] are kept at a distance and welded with the base plate [4B]. The centre of the I beam [4A] is kept at a distance from the edge of the base The tubes [4C] are welded at the corners on top of the base plate [4B]. The centre of the tubes [4C] are kept at a distance from edge of the base plate [4B].

Height adjustment mechanism(200,Fig-5):
[0059] The height adjustment mechanism [200] comprises of screw jack [5A], tubes [5B] and a base plate [5C]. Multiple tubes [5C] are welded at the corners of bottom of the base plate [5C]. The centre of the tubes [5B] are kept at a distance from edge of the base plate [5C].
[0060] The bottom of the screw jack is substantially circular shaped that is tack welded at the centre of the top of the base plate [4B]. The top of the screw jack is tack welded at the centre of the bottom of the base plate [5C]. The screw jack is having rectilinear thread and is provided with handle.
[0061] The tubes [5C] are inserted in the individual tubes [4C] so that the tubes [5C] can move freely inside the individual tubes [4C] when the screw jack [5A] is rotated by handle. The purpose of the screw jack is to do height adjustment.

Cross movement mechanism (300, Fig-6):
[0062] The cross movement mechanism comprises of one plate [6K], substantially v-shaped plate [6M], multiple cotter rods [6F], fasteners including nut [61], rectilinear threaded rod with handle [6H], half circle tube [6B], rollers [6G].

[0063] The plates [6J] are welded at each corner of the top base plate [5C]. Each of two plates [6J] are welded With two individual tubes [ 6L] on the top of the base plate. The bottom of the I-beam [6A] is welded on the top of the centre of the base plate [5C]. The bottom of each Lug of the I-beam [6A] is provided with holes [6D] at a distance from edge of the I-beam lug so that individual rods [6F] can travel through the hole [6D]. At least Two substantially v-shaped rollers [6G] is inserted in each rod [6È] and the distance between the roller to roller is maintained. The rods [6F] are tack welded with the hole [6D] so that the rod should not move. Cotter pin [6N] is provided next to each rollers [6G] to avoid misalignment of rollers. The purpose of the total set up is to provide cross movement of the device above the top of the base plate. The outer face of the lug of I-Beam is welded with a plate [6C] at each side. Each plate is welded at the centre of the half circle tube [6B]. For cross movement, a plate [6K] is welded at the centre of the base plate [5C]. Centre of the plate [6K] is drilled with hole. Exactly opposite side of the base plate [5c] a substantially v-shaped plate [6M] is welded, in which Centre of the v -shaped plate [6M] is also drilled with a hole. The centre of the I-beam [6A] is provided with holes [6E] for the provision of box nut [61]. The box nut [61] is fixed with the I-beam [6A] by nut. A rectilinear including square thread [61-1] with handle is inserted between the two holes of opposite plates [6K,6M] and guided in between the box nut [61].

[0064] For cross movement, the handle is rotated, so that due to the box nut mechanism the total set up can be moved. The half circle tubes [6B] are freely moved on the tubes [6L] depending upon the handle rotation.

linear movement mechanism(400, Fig-7):
[0065] The linear movement mechanism comprises of a base plate [7A], linear movement guide mechanism. The linear movement guide mechanism comprises of a base plate [7B], at least two rails [7G], one top base plate with substantially v-groove [7F] moved on the rail, a rectilinear tread with handle [7D], at least two side plates [7C] and a box nut [7E].

[0066] On the top of the I Beam [6A], a base plate [7A] is welded. Holes are drilled at the centre of the base plate [7A].LM guide comprises of a base plate [7B] which is having the hole dimension same as the base the edge of the top of the base plate at least two rails are tack welded. Both end of the rails are welded with two side plates [7C].The side plates [7C] are having holes at centre so that the screw rod with rectilinear thread with handle can be moved easily inside the hole. A top base plate with substantially v groove [7f] is placed on the rail. The top base plate [7F] is having holes at the centre so that a box nut [7E] can be fitted through bolt. The screw rod is passed through the box nut so that by rotating the handle, the system can be moved linearly on the rail. The base plate with substantially v groove [7F] is having hole at each corner. Another base plate is also having hole at each corner. The two base plates [7F and 7H] are fixed through nut and bolt.

Grinding Mechanism (500, Fig-8):
[0067] One end of the lug [8C] is welded at centre of the C clamp [8A] and other end of the lug is welded at the centre of the top base plate [7H]. The C-Clamp [8A], in which one end is free and other end is welded with the top base plate [7H]. The two C clamps are having holes at both ends. The purpose of the c-clamps is to hold the grinding machine [8D] tightly by nut and bolt mechanism.

Tube loading with pinch roller mechanism (600, Fig-9):
[0068] The tube loading mechanism comprises of a stand [9A], sets of guide rollers mechanism [9B], substantially v -groove pinch rollers [9C], t channels [9F and 9G].
[0069] Guide roller set up [9B] (two rollers are kept in box) is welded at a distance from the edge of the stand [9A]. Exactly other side of the stand [9A] a v-groove pinch r is welded such that the centre line of guide roller [9B] and pinch roller [9C] should be in line.
[0070] On the top of the stand, at least two tubes [9E] are welded. On the two tubes a channel is welded. Another tube [9D] is also welded on the stand. Another channel [9G] is welded at the edge of the channel [9F] and top of the tube [9D] is in inclined position.
[0071] A hole is provided at the end of the channel [9F] to insert a tube [9H] so that tube can be arrested on the loading stand.

Tube rotation mechanism(700,Fig.10):
[0072] The tube rotation mechanism [700] comprises of a bed [10B] and 3 jaw universal chuck [10A].
[0073] The bed is made of rectilinear box. On the top of the bed [10B] an I-ChanneI [10C] is welded. The channel is having holes at the centre. A 3 jaw chuck [10A] is fixed on the top of the I-channel [10C] through nut and bolt mechanism.

Dust collector unit (800, Fig-11):
[0074] The dust collector unit is prepared of thin sheets. A Plurality of thin sheets are welded to each other to form the dust collector. A curved sheet is placed inside the box to guide the grinding particles inside the box.
[0075] The set-up of instant invention is designed with the help of the aforesaid mechanism/means/unit as best seen in Figure 12. Here, the Tube loading with pinch roller mechanism/means [600] is provided in a pair maintaining a gap there between. Assembly of bed [100], height adjustment means [200], cross movement means [300], Linear movement means [400] and grinding means [500] is placed in the gap i.e. between the pinch roller mechanism/means [600] for grinding of the tubes and their butt joint welding area [1]. The tube rotation mechanism/means [700, Fig.10] is provided at one end of said set-up for automatic rotation of the tubes [1]. A dust collector unit [800, Fig-11] is placed below the grinding area adjacent to the assembly of various means so as automatically collect dust post grinding of the tubes [1].

[0076] A method for grinding of butt joint welding areas of tubes [1] of water wall panels for high pressure boilers comprising the following steps: -

- Tubes [1] to be grinded are loaded on the stand [9A] of Tube loading with pinch roller mechanism/means [600].
- The tube [1] which is to be grinded is just rotated from the stand [9A] manually and is automatically placed on the pinch roller [9C] by gravity due to the provision of taper in the stand [9A]. A stopper [9H] which is a small tube, is inserted in the hole provided in the stand [9A] to stop other tubes to fall down. To move one tube on the pinch roller [9C], the stopper [9H] is removed and the tube is moved.
- Tube [1] to be grinded is placed on the bed [100] of the grinding mechanism.
- The end of the tube [1] is held and centred in the 3 jaw universal chuck [10A] of the tube rotation means [700].
- The grinding wheel is placed against the grinding area by the Linear Movement guide mechanism [400].
- The grinding machine and the 3 jaw chuck [10A] is connected with compressed air through different air lines.
- Once all the setting is ok, the air valve is opened and grinding is started.
- The tube [1] is rotated slowly by the 3 jaw chuck [10A] automatically and the feed is also given for grinding manually by rotating the handle through the cross movement mechanism [300] and linear movement mechanism [400].
- The dust is automatically collected in the dust collector [800] which is placed just below the grinding area. Once the dust collector is full, it is despatched to a safe place.
- Once the grinding is completed, the tube [1] is rotated in the nearby dump [D] for storage.
- To do grinding another tube [1] the above said same process is continued.

Benefits in term of Productivity:
Benefits in term of
Productivity:
In the conventional method of grinding the butt joint areas, the contract employees are able to do maximum of 50 joints per day. But the total numbers of tubes requirement for panel shop to be grinded for panel formation is approximately 150.So it was very difficult to supply grinded tubes of required quantity and most of the time the machines are idle due to want of load. In new method of grinding, as there is no human effort for grinding, So, in one shift total 150 joints are grinded easily. There is no machine idle time due to the new method of grinding.
This improves the productivity.
For grinding by conventional method, contract employees are required for grinding and 2 apprentice is required for tilting and holding the tubes while grinding. Total 3 man powers required for grinding of one tubes.

In the new method, as holding and tilting is done through the 3 jaw chuck itself, so only one employee is sufficient for doing grinding of 150 tubes. The extra man powers required by the conventional method is totally eliminated through the present process. The cost to company through the manpower is saved totally.
Quality:
As the feeding for the new method of grinding is uniform through the 1m guide mechanism and cross movement mechanism, so the quality is smooth as per the outer diameter of the tube. It is l00% accepted by our Quality control department persons.
After grinding due to the new method is found fully satisfactory.
Safety and Environment aspects:
Grinding through the conventional process is by holding the grinding machine continuously in hand which is very fatigue and unsafe to the contract employees. This fatigue and unsafe work culture is totally eliminated by the new process.
Operator fatigue is minimized with easy setting.
The grinding material is very harmful for the environment because these iron particles is easily mixed with environment air and inhaling of such polluted air causes incurable diseases. Due to the implementation of the present invention there is total elimination of the iron particles spillage into the air due to the provision of safety cover on the grinding wheel. Also the grinding particles are collected in the dust collector. So, no air pollution occurs.

Health & Working Conditions:
The iron particles were lying on the floor after conventional method of grinding. Complaints were frequently received from workers. After implementation of present invention, this problem is totally eliminated. Safer work condition to thé operator thus promoting higher industrial safety standards and occupational health standards.

Advantageous Features
- Involves automatic operation
- No chance of any reworks
- NO scope of any height variances
- Requirement of less man power
- Avoids slippage thereby ensuring safety
- Less time consumption
- Reduction in fatigue to manpower
- Improvement in quality of finishing job.

Working of Invention
The method of grinding of excess weld areas of butt welding joints of water wall panel tubes comprises the below steps:
- The tubes to be grinded is loaded on the stand with stopper.
- For grinding of the tubes, the Stopper is removed so that one tube is automatically moved to the pinch roller and guide roller of the stand. The pinch rollers and the guide rollers are in line so that the tubes are placed on the two rollers and tubes can be moved front and back and also the rotation of the tubes can be smooth.
- The end of the tube is fixed at the universal 3 jaw chuck. The height of the centre of the universal chuck is same as the height of the tube loaded stand.
- The face of the grinding wheel is adjusted against the extra welded area which is to be grinded.
- The height of the universal grinding machine is adjusted through screw jack. Both linear and cross movement of the grinding machine can be done through the linear and cross movement mechanism.
- The compressed air is connected to the grinding machine and 3 jaw chuck.
- Once all adjustments are ready, the grinding can be started by switching on the compressed air valve.
- Tube is rotated slowly and automatically through the 3 jaw chuck.
- Feed can be given by rotating the handle of the cross movement mechanism by the operator.
- The dust of the grinding particles is collected in the dust collector.
- Once the grinding is finished, the tube can be moved easily into the dump by rotating on the stand.
- For next tube the same process can be repeated.

Test Results

COMPARISON FOR CYCLE TIME

BEFORE IMPLEMENTATION:
Wo DU PENCIL
GRINDER
SETTING TIME
(In hours) MANUAL
GRINDING TIME
(In hours) REWORK
TIME
(In hours) TOTAL
TIME
(IN HRS)
1720-06-751 002 1.5 4 2.5 8
1721-06-751 010 4 2.5 7.5
1723-06-751 003 1.5 4 2.5 8
1816-11-767 002 1.5 4 2 7.5
1816-11-767 003 1.2 4 2 7.2
AVG time taken 1.34 4 2.3 7.64 HRs

AFTER IMPLEMENTATION:

Wo DU GRINDING
MACHINE
SETTING TIME
(In hours) GRINDIN
G TIME
( In hours) REWORK
TIME
( In hours) TOTAL
TIME
(IN HRS)
1830-06-751 001 .10 1.85 1.1
1830-06-751 003 .10 1.6 1.1
1830-06-751 006 .10 1.9 O 1.1
1830-06-751 013 .10 1.85 1.1
1830-06-751 017 .10 1.85 O 1.1
AVG time taken 0.1 1.8 1.9 HRs

SO, AVERAGE REDUCED CYCLE TIME PER PANEL: 5.74 HRS
FINALLY CYCLE TIME REDUCED: 75%

It is to be noted that the present invention is susceptible to modifications, adaptations and changes by those skilled in the art. Such variant embodiments employing the concepts and features of this invention are intended to be within the scope of the present invention, which is further set forth under the following claims:-

WE CLAIM

1. A Set-up for grinding excess weld areas of butt welding joints of water wall panel tubes comprising a pair of Tube loading with pinch roller mechanism/means [600] maintaining a gap there between for supporting the tubes [1] to be grinded, wherein assembly of bed [100], height adjustment means [200], cross movement means [300], Linear movement means [400] and grinding means [500] is placed in the gap [600] for grinding of the weld areas of butt welding joints of water wall panel tubes [1], in which tube rotation mechanism/means [700] is provided at one end of said set-up for automatic rotation of the tubes [1], and a dust collector [800] is placed below the grinding area adjacent to the assembly so as to automatically collect dust post grinding of the tubes [1].

2. The set-up for grinding excess weld areas of butt welding joints of water wall panel tubes as claimed in claim 1, wherein the bed [100] is fabricated by at least two I-Beams [4A], one base plate [4B] and four tubes [4C],in which the two I-beams [4A] are kept at a distance and welded with the base plate [4B], the centre of the I beam [4A] is kept at a distance from the edge of the base plate [4B], the tubes [4C] are welded at the corners on top of the base plate [4B], and the centre of the tubes [4C] are kept at a distance from edge of the base plate [4B].

3. The set-up for grinding excess weld areas of butt welding joints of water wall panel tubes as claimed in claim 1 or 2, wherein the height adjustment mechanism [200] comprises of screw jack [5A], tubes [5B] and a base plate [5C], in which multiple tubes [5C] are welded at the corners of bottom of the base plate [5C], the centre of the tubes [5B is kept at a distance from edge of the base plate [5C], wherein the bottom of the screw jack is welded at the centre of the top of the base plate [4B], the top of the screw jack is welded at the centre of the bottom of the base plate [5C], in which the screw jack is having rectilinear thread and is provided with handle, the tubes [5C] are inserted in the individual tubes [4C] that the tubes [5C] can move freely inside the individual tubes [4C] when the screw jack [5A] is rotated by handle.

4. The set-up for grinding excess weld areas of butt welding joints of water wall panel tubes as claimed in claims 1-3, wherein the cross movement mechanism comprises of one plate [6K], substantially v-shaped plate [6M], multiple cutter rods [6F], fasteners including nut [61], rectilinear threaded rod with handle [6H], half circle tube [6B], rollers [6G], in which plates [6J] are welded at each corner of the top base plate [5C], each of two plates [6J] is welded with two individual tubes [6L] on the top of the base plate, the bottom of the I-beam [6A] is welded on the top of the centre of the base plate [5C], the bottom of each Lug of the I-beam [6A] is provided with holes [6D] at a distance from edge of the I-beam lug that individual rods [6F] can travel through the hole [6D], in which at least Two substantially v-shaped rollers [6G] are inserted in each rod [6È] and the distance between the roller to roller is maintained, wherein the rods [6F] are welded with the hole [6D] that the rod should not move, Cotter pin [6N] is provided next to each rollers [6G] to avoid misalignment of rollers, the outer face of the lug of I-Beam is welded with a plate [6C] at each side and Each plate is welded at the centre of the half circle tube [6B].

5. The set-up for grinding excess weld areas of butt welding joints of water wall panel tubes as claimed in claim 4, wherein for the cross movement, a plate [6K] is welded at the centre of the base plate [5C], Centre of the plate [6K] is having hole, in which opposite side of the base plate [5c] a substantially v-shaped plate [6M] is welded, in which Centre of the v -shaped plate [6M] is having a hole, the centre of the I-beam [6A] is provided with holes [6E] for the provision of box nut [61], the box nut [61] is fixed with the I-beam [6A] by nut, wherein a rectilinear including square thread [61-1] with handle is inserted between the two holes of opposite plates [6K,6M] and guided in between the box nut [61].

6. The set-up for grinding excess weld areas of butt welding joints of water wall panel tubes as claimed in claims 1-5, wherein the linear movement mechanism comprises of a base plate [7A], linear movement guide mechanism comprising of a base plate [7B], at least two rails [7G], one top base plate with substantially v-groove(7F) moved on the rail, a rectilinear tread with handle [7D], at least two side plates [7C] and a box nut [7E], in which on the top of the I Beam [6A], a base plate [7A] is welded, holes are drilled at the centre of the base plate [7A],the linear movement guide comprises of a base plate [7B] which is having the hole dimension same as the base plate [7A], on the edge of the top of the base plate at least two rails are welded, both end of the rails are welded with two side plates [7C], in which the side plates [7C] are having holes at centre that the screw rod with rectilinear thread with handle can be moved inside the hole, wherein a top base plate with substantially v groove [7f] is placed on the rail, the top base plate [7F] is having holes at the centre that a box nut [7E] is fitted, the screw rod is passed through the box nut that by rotating the handle, the system is moved linearly on the rail, wherein the base plate with substantially v groove [7f] is having hole at each corner and another base plate is having hole at each corner, the two base plates [7F and 7H] are fixed to each other.

7. The set-up for grinding excess weld areas of butt welding joints of water wall panel tubes as claimed in claims 1-6, wherein the Grinding Mechanism [500] comprising of lug [8C],
one end of the lug [8C] is welded at centre of the C clamp [8A] and other end of the lug is welded at the centre of the top base plate [7H], the C-Clamp [8A], one end of which is free and other end is welded with the top base plate [7H], and the two C clamps are having holes at both ends.

8. The set-up for grinding excess weld areas of butt welding joints of water wall panel tubes as claimed in claims 1-7, wherein the tube loading mechanism comprises of a stand [9A], sets of guide rollers mechanism [9B], substantially v -groove pinch rollers [9C], t channels [9F and 9G], in which the Guide roller set up [9B] is welded at a distance from the edge of the stand [9A], other side of the stand [9A] a v-groove pinch r is welded that the centre line of guide roller [9B] and pinch roller [9C] is in line, wherein on the top of the stand, at least two tubes [9E] are welded, on the two tubes a channel is welded, another tube [9D] is welded on the stand, another channel [9G] is welded at the edge of the channel [9F] and top of the tube [9D] is in inclined position, in which a hole is provided at the end of the channel [9F] to insert a tube [9H] that tube is arrested on the loading stand.

9. The set-up for grinding excess weld areas of butt welding joints of water wall panel tubes as claimed in claims 1-8, wherein the tube rotation mechanism [700] comprises of a bed [10B] and 3 jaw universal chuck[10A],the bed is made of rectilinear box, on the top of the bed [10B] an I-ChanneI [10C] is welded, in which the channel is having holes at the centre and the 3 jaw chuck [10A] is fixed on the top of the I-channel [10C];
the dust collector unit is prepared of sheets welded to each other and a curved sheet is placed inside the box to guide the grinding particles inside the box.

10. A method for grinding excess weld areas of butt welding joints of water wall panel tubes comprising the following steps:
tubes [1] to be grinded are loaded on the stand [9A] of Tube loading with pinch roller mechanism/means (600);
the tube [1] to be grinded is rotated from the stand [9A] manually and is automatically placed on the pinch roller [9C] by gravity due to the provision of taper in the stand [9A], in which a stopper [9H] is inserted in the hole provided in the stand [9A] to stop other tubes to fall down;
to move one tube on the pinch roller [9C], the stopper [9S] is removed and the tube is moved;
tube [1] to be grinded is placed on the bed [100] of the grinding mechanism;
the end of the tube [1] is held and centred in the 3 jaw universal chuck [10A] of the tube rotation means [700];
the grinding wheel is placed against the grinding area by the Linear Movement guide mechanism [400];
the grinding machine and the 3 jaw chuck [10A] is connected with compressed air through different air lines;
once all the setting is ok, the air valve is opened and grinding is started;
the tube [1] is rotated by the 3 jaw chuck [10A] automatically and the feed is given for grinding manually by rotating the handle through the cross movement mechanism [300] and linear movement mechanism [400];
the dust is automatically collected in the dust collector [800] which is placed below the grinding area.