Description:FIELD OF THE INVENTION

The present invention relates to the field of thermal processing equipment, particularly within the scope of industrial aluminium extrusion. More specifically, this invention pertains to a single log heater designed to uniformly pre-heat aluminium logs before the extrusion process. This advanced system is engineered to consume less fuel while significantly enhancing the efficiency, productivity, and quality of the extrusion process. It proves especially beneficial in aluminium plants producing industrial profiles, as it not only boosts production rates but also improves the aesthetic quality of the extruded profiles.

BACKGROUND OF THE INVENTION

In the aluminium extrusion industry, the efficiency and precision of the pre-heating process are pivotal to achieving superior product quality and operational effectiveness. Traditional heating methods often fail to deliver uniform temperature distribution, leading to increased fuel consumption and compromised extrusion outcomes. These challenges highlight the urgent need for an innovative solution that can revolutionize the pre-heating phase.

The present invention addresses this need with the development of a state-of-the-art single log heater designed to uniformly pre-heat aluminium logs. This advanced system ensures consistent temperature throughout each log, significantly enhancing fuel efficiency and reducing operational costs. Its application is particularly advantageous for aluminium plants focused on producing industrial profiles, where it not only boosts production rates but also elevates the aesthetic and structural quality of the profiles.

This invention's benefits extend far beyond energy savings. The uniform temperature distribution it achieves enhances the brightness and hardness of the extruded profiles, resulting in products with superior visual appeal and durability. Moreover, the consistent heating reduces thermal stress on the dies, thereby increasing their lifespan and minimizing maintenance downtime. By integrating this innovative single log heater, aluminium extrusion plants can achieve unprecedented levels of efficiency, product quality, and cost-effectiveness, making it a crucial advancement in the field of thermal processing technology.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

These and other features, aspect, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein the device and process and digester configurations described in the present invention are explained in more detail with reference to the following drawings:

Figure 1 illustrates the external schematic view of the log heater.

While the invention is described in conjunction with the illustrated embodiment, it is understood that it is not intended to limit the invention to such embodiment. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the invention disclosure as defined by the claims.

SUMMARY OF THE INVENTION
This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention nor is it intended to determine the scope of the invention.
In an aspect of the present invention, there is provided a heater (21) for single aluminum log comprising:
a mild-steel (hot rolled sheets) structure from the outside and stainless steel (SS 304) structure from the inside comprising a log heater (21) with a moveable roof (14) in the first half connected to a log storage table (13) in the second half assembled to form a curved roof structure in its first half, transitioning into a table-shaped configuration in the second half, forming a hybrid assembly;

an external roof structure of the log heater (21) in the first half comprising the moveable roof (14) and an ID Fan (10) installed on it;

an external structure of the log heater (21) in the second half comprising the log storage table (13), a plurality of chain driver pusher (11) and a tilting mechanism (12);

an external side structure of the log heater (21) at the front side of the log heater (21) comprising a burner (1), a door (2) and a servo control air valve (6); and

an external side structure of the log heater (21) at the right side of the door (2) comprising a spring loaded thermocouple (3), a pilot burner (4), an air gas mixture (5), a solenoid valve (7), an air gas regulator (8), a pre mix burner (9), a SS special fabricator roller (15), a burner blower (16), a bearing cooling blower (17), a primary gas train (18), a secondary gas train (19) and a pneumatic cylinder (20).

In an embodiment of the present invention, there is provided a single log heater (21), wherein the outer structure is made up of mild-steel (hot rolled sheets) and inner structure is made up of stainless steel (SS 304).

In another embodiment of the present invention, there is provided a single log heater (21), wherein the heater (21) is provided with a moveable roof (14) installed on the first half portion and having an ID fan (10) connected to it for heat circulation in the chamber.

In yet another embodiment of the present invention, there is provided a single log heater (21), wherein the aluminum rod enters into the heater (21) through a Door (2).

In still another embodiment of the present invention, there is provided a single log heater (21), wherein the heater (21) comprises a Burner (1) installed in front of furnace for proper billet heating.

In an embodiment of the present invention, there is provided a single log heater (21), wherein the heater (21) further comprises a servo control air butterfly valve (6) to automatically open and close the butterfly valve through a servo control motor.

In another embodiment of the present invention, there is provided a single log heater (21), wherein the heater (21) comprises a log storage table (13) having a capacity to hold 10 logs for storing log stock, a chain driver pusher (11) to push forward or reverse pull the log inside or outside the burner respectively.

In yet another embodiment of the present invention, there is provided a single log heater (21), wherein the heater (21) further comprises a spring loaded thermocouple (3) to sense the temperature inside the heater, a pilot burner (4) which helps in the firing of premixed burner, a fabricated chamber of pipe called an air gas mixture (5) to hold a mixture of air and LPG/PNG/CNG.

In still another embodiment of the present invention, there is provided a single log heater (21), wherein the heater (21) further comprises a solenoid valve (7) to provide gas by electric magnetic quill, an air gas regulator (8) to regulate the mixture of air and gas, and a pre mix burner (9) for the purposes of fast heating and soaking.

In an embodiment of the present invention, there is provided a single log heater (21), wherein the heater (21) further comprises a SS special fabricated roller (15) for the moment of logs, a burner blower (16) to provide oxygen for combustion, and a bearing cooling blower (17) to keep the bearing cool.

In another embodiment of the present invention, there is provided a single log heater (21), wherein the heater (21) comprises a primary gas train (18) for safety and control of natural gas engine and/ or burner, a secondary gas train (19) to ensure safe operation of the gas equipment, and a pneumatic cylinder (20) to control the movement of thermocouple (3) and door (2).

These and other features, aspects, and advantages of the present subject matter will be better understood with reference to the following description. This summary is provided to introduce a selection of concepts in a simplified form.

DETAILED DESCRIPTION OF THE INVENTION

Those skilled in the art will be aware that the present disclosure is subject to variations and modifications other than those specifically described. It is to be understood that the present disclosure includes all such variations and modifications. The disclosure also includes all such steps of the process, features of the invention, referred to or indicated in this specification, individually or collectively, and any and all combinations of any or more of such steps or features.

Definitions
For convenience, before further description of the present disclosure, certain terms employed in the specification, and examples are collected here. These definitions should be read in the light of the remainder of the disclosure and understood as by a person skilled in the art. The terms used herein have the meanings recognized and known to those of skill in the art, however, for convenience and completeness, particular terms and their meanings are set forth below.

The articles “a”, “an” and “the” are used to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article. The terms “comprise” and “comprising” are used in the inclusive, open sense, meaning that additional elements may be included. It is not intended to be construed as “consists of only”. Throughout this specification, unless the context requires otherwise the word “comprise”, and variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated element or step or group of elements or steps but not the exclusion of any other element or step or group of elements or steps.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the preferred methods and materials are now described. All publications mentioned herein are incorporated herein by reference. The present disclosure is not to be limited in scope by the specific embodiments described herein, which are intended for the purposes of exemplification only. Functionally equivalent products and methods are clearly within the scope of the disclosure, as described herein.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

While the invention is susceptible to various modifications and/or alternative adaptations, specific embodiments thereof has been shown by way of examples and will be described in detail below. However, it should be understood, that it is not intended to limit the invention to the particular structural arrangement disclosed, but on the contrary, the invention is to cover all modifications, structural adaptations and alternative falling within the spirit and the scope of the invention as defined herein.

The present invention relates to the field of thermal processing equipment, particularly within the scope of industrial aluminium extrusion. More specifically, this invention pertains to a single log heater designed to uniformly pre-heat aluminium logs before the extrusion process. This advanced system is engineered to consume less fuel while significantly enhancing the efficiency, productivity, and quality of the extrusion process. It proves especially beneficial in aluminium plants producing industrial profiles, as it not only boosts production rates but also improves the aesthetic quality of the extruded profiles.

Thus, in accordance with the present invention there is provided a heater (21) for single aluminum log comprising:
a mild-steel (hot rolled sheets) structure from the outside and stainless steel (SS 304) structure from the inside comprising a log heater (21) with a moveable roof (14) in the first half connected to a log storage table (13) in the second half assembled to form a curved roof structure in its first half, transitioning into a table-shaped configuration in the second half, forming a hybrid assembly;
an external roof structure of the log heater (21) in the first half comprising the moveable roof (14) and an ID Fan (10) installed on it;
an external structure of the log heater (21) in the second half comprising the log storage table (13), a plurality of chain driver pusher (11) and a tilting mechanism (12);
an external side structure of the log heater (21) at the front side of the log heater (21) comprising a burner (1), a door (2) and a servo control air valve (6); and
an external side structure of the log heater (21) at the right side of the door (2) comprising a spring loaded thermocouple (3), a pilot burner (4), an air gas mixture (5), a solenoid valve (7), an air gas regulator (8), a pre mix burner (9), a SS special fabricator roller (15), a burner blower (16), a bearing cooling blower (17), a primary gas train (18), a secondary gas train (19) and a pneumatic cylinder (20).

Figure 1 is a log heater that is constructed in accordance with a preferred embodiment of the present invention. The present invention provides an advanced single log heater (21) for pre-heating aluminum logs used in the extrusion process. This innovative heater is designed to ensure uniform temperature distribution, significantly enhancing the efficiency, productivity, and quality of the extrusion process. The outer structure of the heater is crafted from mild-steel (hot rolled sheets), while the inner structure is constructed from stainless steel (SS 304), ensuring durability and effective thermal management.

At the heart of this invention is the moveable roof (14) located in the first half of the heater, seamlessly transitioning into a log storage table (13) in the second half. This hybrid assembly, which features a curved roof in its first half and a table-shaped configuration in the second half, is designed to optimize the handling and heating of aluminum logs. The moveable roof (14) is equipped with an ID Fan (10) that circulates heat within the chamber, ensuring uniform temperature distribution throughout the logs.

Aluminum logs are introduced into the heater (21) through a strategically designed door (2) that prevents heat loss and enhances heating efficiency. Positioned at the front of the furnace is a high-performance burner (1), which ensures proper billet heating. To optimize combustion, the heater is equipped with a servo control air butterfly valve (6) that automatically adjusts air flow. This automated control system not only improves fuel efficiency but also ensures consistent heating, which is crucial for high-quality extrusion outcomes.

The log storage table (13) within the heater has a capacity to hold up to 10 logs, facilitating efficient stock management and reducing downtime between heating cycles. Integrated into this system is a chain driver pusher (11), which precisely moves logs into and out of the burner. Additionally, a tilting mechanism (12) assists in transferring logs from the storage table to the heating chamber, ensuring smooth and continuous operation.

To maintain precise temperature control, the heater employs a spring-loaded thermocouple (3) that provides accurate temperature readings. This ensures consistent heating and helps in achieving the desired properties in the extruded profiles. A pilot burner (4) is included to assist in the ignition of the pre-mix burner (9), which is utilized for fast heating and soaking purposes. The air gas mixture (5) chamber, a fabricated assembly of pipes, holds a mixture of air and LPG/PNG/CNG, ensuring optimal combustion conditions.

The heater also incorporates several advanced features to enhance its overall functionality and efficiency. A solenoid valve (7) precisely controls the gas flow using an electric magnetic quill, while the air gas regulator (8) adjusts the mixture of air and gas to optimize combustion. Inside the heating chamber, SS special fabricated rollers (15) facilitate the smooth movement of logs, ensuring they are evenly heated. A burner blower (16) supplies oxygen to the burner, which is essential for effective combustion, while a bearing cooling blower (17) keeps the bearings cool, thereby extending their lifespan and reducing maintenance needs.

For safety and control, the heater includes primary (18) and secondary gas trains (19). These components ensure a controlled and safe gas supply, preventing potential hazards and ensuring reliable operation. Additionally, a pneumatic cylinder (20) controls the movement of the thermocouple (3) and door (2), further enhancing the heater's operational efficiency and reliability.

Working Principle
The working principle of the single log heater (21) revolves around ensuring uniform and efficient pre-heating of aluminum logs before extrusion. Logs are loaded onto the log storage table (13), which holds up to 10 logs at a time. The chain driver pusher (11) moves the logs sequentially into the heating chamber through the door (2). Once inside, the burner (1) provides targeted heating to the logs, while the ID Fan (10) circulates hot air to maintain uniform temperature distribution.

The moveable roof (14) and the integrated servo control air butterfly valve (6) play critical roles in regulating the internal environment, ensuring optimal combustion and heat efficiency. The temperature is continuously monitored by the spring-loaded thermocouple (3), which adjusts the heating process as necessary. The pilot burner (4) ignites the pre-mix burner (9) for rapid heating and soaking, ensuring the logs reach the desired temperature uniformly. The air gas mixture (5) chamber ensures the proper mix of fuel and air, enhancing combustion efficiency and reducing fuel consumption.

Advantages
The single log heater (21) offers several significant advantages that mark it as a substantial advancement in thermal processing technology. The uniform heating capability ensures consistent temperature distribution, significantly improving the quality of extruded profiles. This uniformity enhances the brightness and hardness of the extruded profiles, resulting in products with superior visual appeal and durability. The energy efficiency of this system reduces fuel consumption, lowering operational costs and contributing to a more sustainable operation.

Moreover, the consistent heating reduces thermal stress on the dies, extending their lifespan and minimizing maintenance downtime. The automated control features, including the servo control air butterfly valve (6) and the chain driver pusher (11), enhance overall efficiency and productivity, making the heater highly reliable and easy to operate. The integration of safety features, such as the primary (18) and secondary gas trains (19), ensures safe and controlled gas supply, preventing potential hazards and ensuring reliable operation.

By incorporating this innovative single log heater, aluminum extrusion plants can achieve significant improvements in efficiency, product quality, and cost-effectiveness. This invention represents a crucial advancement in thermal processing equipment, providing a robust solution to the challenges faced in the pre-heating phase of aluminum extrusion, thereby revolutionizing the industry.
, Claims:We Claim:

1. A heater (21) for single aluminum log comprising:

a mild-steel (hot rolled sheets) structure from the outside and stainless steel (SS 304) structure from the inside comprising a log heater (21) with a moveable roof (14) in the first half connected to a log storage table (13) in the second half assembled to form a curved roof structure in its first half, transitioning into a table-shaped configuration in the second half, forming a hybrid assembly;

an external roof structure of the log heater (21) in the first half comprising the moveable roof (14) and an ID Fan (10) installed on it;

an external structure of the log heater (21) in the second half comprising the log storage table (13), a plurality of chain driver pusher (11) and a tilting mechanism (12);

an external side structure of the log heater (21) at the front side of the log heater (21) comprising a burner (1), a door (2) and a servo control air valve (6); and

an external side structure of the log heater (21) at the right side of the door (2) comprising a spring loaded thermocouple (3), a pilot burner (4), an air gas mixture (5), a solenoid valve (7), an air gas regulator (8), a pre mix burner (9), a SS special fabricator roller (15), a burner blower (16), a bearing cooling blower (17), a primary gas train (18), a secondary gas train (19) and a pneumatic cylinder (20).

2. The heater (21) as claimed in claim 1, wherein the outer structure is made up of mild-steel (hot rolled sheets) and inner structure is made up of stainless steel (SS 304).

3. The heater (21) as claimed in claim 1-2, wherein the heater (21) is provided with a moveable roof (14) installed on the first half portion and having an ID fan (10) connected to it for heat circulation in the chamber.

4. The heater (21) as claimed in claim 1, wherein the aluminum rod enters into the heater (21) through a Door (2).

5. The heater (21) as claimed in claim 1, wherein the heater (21) comprises a Burner (1) installed in front of furnace for proper billet heating.

6. The heater (21) as claimed in claim 1, wherein the heater (21) further comprises a servo control air butterfly valve (6) to automatically open and close the butterfly valve through a servo control motor.

7. The heater (21) as claimed in claim 1, wherein the heater (21) comprises a log storage table (13) having a capacity to hold 10 logs for storing log stock, a chain driver pusher (11) to push forward or reverse pull the log inside or outside the burner respectively.

8. The heater (21) as claimed in claim 1, wherein the heater (21) further comprises a spring loaded thermocouple (3) to sense the temperature inside the heater, a pilot burner (4) which helps in the firing of premixed burner, a fabricated chamber of pipe called an air gas mixture (5) to hold a mixture of air and LPG/PNG/CNG.

9. The heater (21) as claimed in claim 1, wherein the heater (21) further comprises a solenoid valve (7) to provide gas by electric magnetic quill, an air gas regulator (8) to regulate the mixture of air and gas, and a pre mix burner (9) for the purposes of fast heating and soaking.

10. The heater (21) as claimed in claim 1, wherein the heater (21) further comprises a SS special fabricated roller (15) for the moment of logs, a burner blower (16) to provide oxygen for combustion, and a bearing cooling blower (17) to keep the bearing cool.

11. The heater (21) as claimed in claim 1, wherein the heater (21) comprises a primary gas train (18) for safety and control of natural gas engine and/ or burner, a secondary gas train (19) to ensure safe operation of the gas equipment, and a pneumatic cylinder (20) to control the movement of thermocouple (3) and door (2).