Apparatus for automatic welding in wheel collar to bring back collar thickness and re-use wheel of crane

Abstract

ABSTRACT “APPARATUS FOR AUTOMATIC WELDING IN WHEEL COLLAR TO BRING BACK COLLAR THICKNESS AND RE-USE WHEEL OF CRANE” This invention relates to apparatus for automatic welding in wheel collar to bring back collar thickness and re-use wheel of crane. The invention exploits the method of motorized gear mechanism to achieve rotation of wheel. The welding head comprises of welding torch and wire feed motor mounted in a fixture. The height of the welding torch can be adjusted with the help of vertical adjustment mechanism for vertical movement and horizontal screw for horizontal movement. Designed fixture holds all size of wheel. The speed of the gear drive mechanism is regulated with a variable frequency drive mechanism to regulate the speed of the wheel for proper collar welding and the control of the same is provided in a control panel. Hence, with the help of automatic wheel rotation, welding in the collar area is achieved to increase the collar thickness. (Figure: 3)

Description

FIELD OF INVENTION:

[001] The invention relates to an apparatus for automatic Welding in Wheel Collar tobring back collar thickness and re-use wheel of crane. In the proposed invention themethod of 'automatic welding in wheel collar', the wheel is thus re-used therebyavoiding for replacement of new wheel.BACKGROUND OF THE INVENTION:

[002] Background description includes information that may be useful inunderstanding the present invention. It is not an admission that any of the informationprovided herein is prior art or relevant to the presently claimed invention, or that anypublication specifically or implicitly referenced is prior art.

[003] In all the manufacturing industries, EOT Crane (Electric Overhead Travelling)are the most commonly used type of crane that are used to lift or lower the loads aswell as to move heavy materials during daily operations. Some of the majorcomponents of Cranes include Girders, End Carriages, LT mechanism, trolley, Hookblock, operator cabin, wheel assembly which houses the wheel. The girders areattached at each end to the end carriages which has the wheel assembly. An EOT cranehas minimum 4 wheels for Long travel mechanism that run along the runway rail.

[004] Wear and tear of wheels in Long travel mechanism in EOT cranes happen dueto misalignment of wheel or runway rail. Disposal of Crane wheels is requiredwhenever there is a wear and tear of more than 80% collar thickness of the Wheels.New wheels will be provided in that place as a replacement. The wheels becomeunusable and unsafe if the wheel collar thickness has reduced more than 80% as thereis possibility of derail of the EOT Cranes if the collar has totally worn out. Hence, ingeneral practice such wheels are disposed as scrap and are replaced with new wheels.

[005] In most of the heavy industries, there are EOT Cranes in sizeable numbers withdifferent capacities. Usually wheel diameter varies based on the capacity of the crane.With sizeable numbers of EOT Cranes, the number of wheels will come in thousands.Cost of wheels varies with diameter and life of wheels comes around 20 years'maximum if there is less wear and tear in collar and also depends on the condition ofthe crane wheel alignment. In some cases, the life comes around 5 years also due tomisalignment of wheels or rail.

[006] Wheel spare has to be procured in Lakh Rupees and maintained yearly as areplacement for worn out wheels. To save the cost of wheel replacement annually, asystem has been developed that is very functional in automatic welding of wheel collarsof all the sizes in the least possible time. Also where the human resource is efficientlyengaged.

[007] There is no prior art related to increasing the thickness of wheel collar byautomatic welding.OBJECTS OF THE INVENTION:

[008] Primary objective of the invention is to provide an apparatus for automaticwelding in Wheel Collar to bring back collar thickness and re-use wheel of crane.

[009] An objective of the invention is to provide an automatic welding of wheelcollars for all the sizes of wheels and avoid the cost of new wheel procurement.

[0010] Another objective of this invention is to engage less human resource byeliminating the manual involvement during welding as due to the oval size of thewheels, manual welding is difficult for practical implementation for proper welding.

[0011] Yet another objective of this invention is to minimize the humanresource (welder) requirement as the work is carried out automatically.

[0012] Still another objective of this invention is to provide an apparatus forautomatic welding in Wheel Collar to bring back collar thickness and re-use wheel ofcrane, wherein no machining is required after welding.

[0013] These and other objects and advantages of the present invention will beapparent to those skilled in the art after a consideration of the following detaileddescription taken in conjunction with the accompanying drawings in which a preferredform of the present invention is illustrated.SUMMARY OF THE INVENTION:

[0014] One or more drawbacks of conventional systems and process areovercome, and additional advantages are provided through the apparatus / compositionand a method as claimed in the present disclosure. Additional features and advantagesare realized through the technicalities of the present disclosure. Other embodimentsand aspects of the disclosure are described in detail herein and are considered to be partof the claimed disclosure.

[0015] This invention exploits the method of motorized gear mechanism toachieve rotation of wheel. The welding head consists of welding head and wire feedmotor mounted in a fixture as seen in Fig-3 (side view). The height of the welding torchcan be adjusted with the help of vertical adjustment mechanism for vertical movementand horizontal screw for horizontal movement. Designed fixture will hold all size ofwheel Fig-3 (key plan). The speed of the gear drive mechanism is regulated with avariable frequency drive mechanism to regulate the speed of the wheel for proper collarwelding and the control of the same is provided in a control panel. The power supplycable to the welding power source is fixed. This gives the operator the full control ofthe automatic mechanism for start and stop of the welding process. Hence the weldingof the wheel collar is carried out automatically.

[0016] Various objects, features, aspects, and advantages of the inventivesubject matter will become more apparent from the following detailed description ofpreferred embodiments, along with the accompanying drawing figures in which likenumerals represent like components.

[0017] It is to be understood that the aspects and embodiments of the disclosuredescribed above may be used in any combination with each other. Several of the aspectsand embodiments may be combined to form a further embodiment of the disclosure.

[0018] The foregoing summary is illustrative only and is not intended to be inany way limiting. In addition to the illustrative aspects, embodiments, and featuresdescribed above, further aspects, embodiments, and features will become apparent byreference to the drawings and the following detailed description.BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:

[0019] The illustrated embodiments of the subject matter will be bestunderstood by reference to the drawings, wherein like parts are designated by likenumerals throughout. The following description is intended only by way of example,and simply illustrates certain selected embodiments of devices, systems, and processesthat are consistent with the subject matter as claimed herein, wherein:Figure 1A shows: A general view of Electric Overhead Travelling (EOT) crane andits components, which indicates as follows:Crab / Trolley - 101LT Mechanism - 102Girder - 103End Carriage - 104Hook Block - 105Platform - 106Operation cabin - 107Runway rail - 108Wheel - 2Wheel Assembly - 109Figure 1 shows: A general view of Structural components design of the apparatus forwheel collar welding.Figure 2 shows: Line diagram for Power transmission for rotating the wheel duringwelding to prepare the wheel collar, which indicates as follows:Variable Frequency Drive - VFDMotor - 200Worm Gearbox - 201Chain Drive - 202Gear Box - 1kDrive Roller - 1gIdler Roller - 1hWheel - 2Wire Feeder - 1aCO2 Welding Machine - WMFigure 3 shows: Key plan and side view of the apparatus for wheel collar welding,which indicates as follows:Roller for rolling the wheel - 1dIdler roller - 1hWheel Collar - WCJob-Crane wheel - 2Drive roller - 1gBRG. Housing - 300Drive Gear - 1eDriven Gear - 1fPlumber Box - 1nGear Box - 1kFlange - 1mChain Sprocket - SCoupling - 1jFrom VFD Panel for Motor speed control - 301Main Motor - MDrive Shaft - DVertical adjustment - 1bWire Feeder - 1aHorizontal Adjustment - 1cFrom CO2 Welding Machine - 302Figure 4 shows: Stages of work carried out with the apparatus for collar welding,wherein:Fig.4A shows Loading the Crane wheel whose collar is to be welded.Fig.4B shows Wheel collar welding to regain the collar thickness (along withpre-heating).Figure 5A shows: Before welding with the apparatus.Figure 5B shows: After welding with the apparatus.

[0020] The figures depict embodiments of the disclosure for purposes ofillustration only. One skilled in the art will readily recognize from the followingdescription that alternative embodiments of the structures and methods illustratedherein may be employed without departing from the principles of the disclosuredescribed herein.DETAIL DESCRIPTION OF THE PRESENT INVENTION WITHREFERENCE TO THE ACCOMPANYING DRAWINGS OF PREFERREDEMBODIMENTS:

[0021] While the embodiments of the disclosure are subject to variousmodifications and alternative forms, specific embodiment thereof have been shown byway 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, equivalents, andalternative falling within the scope of the disclosure.

[0022] The present invention makes a disclosure regarding an inventionpertaining to an apparatus for automatic Welding in Wheel Collar to bring back collarthickness and re-use wheel of crane.

[0023] Reference may be made to Figure 3 illustrating Key plan for wheelcollar welding machine, which shows the structural components design that holds androtates the wheel (2), that includes the support for horizontal movement of weldingtorch and wire feeder (1a), geared motor, drive roller(1g) and idler roller(1h). The driveroller speed is controlled by Variable Frequency Drive (VFD) through the controlpanel. Here, CO2 welding power source is used to carry out the welding process on thewheel (2) so as to increase the collar thickness.

[0024] Figure-2 shows the single line diagram showing the mechanism to rotatethe wheel during welding to cover the welding cycle automatically. Also as shown inFigure-3, the newly developed apparatus and method for the Wheel collar weldingcomprises of:

[0025] Vertical Adjustment (1b) and Horizontal Adjustment (1c): CO2Welding Torch and Wire feeder (1a) location on the job wheel (2) is adjusted with thehelp of the vertical adjustment depending on the height of the wheel and horizontaladjustment comprising of screw rod depending on the width of the wheel.

[0026] Coupling (1j): This is a mechanical element to connect the main motorshaft with the gearbox shaft. The speed of the main motor shaft is adjusted by thevariable frequency drive (VFD) depending on the required thickness of the welding onthe job wheel (2).

[0027] Drive gear (1e): This is a mechanical element that transfers power fromthe chain sprocket to the drive roller (1g) that is used to rotate the job wheel (2). Theidler rollers (1d, 1h) support in the rotation of the job wheel.

[0028] Variable Frequency Drive (VFD) Panel: This is an electrical panel,that provides power supply to the VFD and also has the adjustment mechanism foradjusting the speed of the Drive that helps in adjusting the job wheel speed.

[0029] CO2 Welding Machine: This is a welding power source that includeswelding torch and wire feeder (1a) for welding on the job wheel (2) where the collarthickness is to be increased.ADVANTAGES OF INVENTION:

[0030] To provide an automatic welding of wheel collars for all the sizes ofwheels and avoid the cost of new wheel procurement.

[0031] Due to the oval size of the wheels, manual welding will be difficult forpractical implementation for proper welding. To engage less human resource byeliminating the manual involvement during welding.

[0032] To minimize the human resource (welder) requirement as the work iscarried out automatically.

[0033] After welding, no machining is required.RESULTS AFTER USING THE RE-USED WHEEL IN CRANES:

[0034] Observed the wheels were functioning same as the new wheels.

[0035] Each of the appended claims defines a separate invention, which forinfringement purposes is recognized as including equivalents to the various elementsor limitations specified in the claims. Depending on the context, all references belowto the "invention" may in some cases refer to certain specific embodiments only. Inother cases, it will be recognized that references to the "invention" will refer to subjectmatter recited in one or more, but not necessarily all, of the claims.

[0036] Groupings of alternative elements or embodiments of the inventiondisclosed herein are not to be construed as limitations. Each group member can bereferred to and claimed individually or in any combination with other members of thegroup or other elements found herein. One or more members of a group can be includedin, or deleted from, a group for reasons of convenience and / or patentability. When anysuch inclusion or deletion occurs, the specification is herein deemed to contain thegroup as modified thus fulfilling the written description of all groups used in theappended claims.

[0037] It will be understood by those within the art that, in general, terms usedherein, and especially in the appended claims (e.g., bodies of the appended claims) aregenerally intended as "open" terms (e.g., the term "including" should be interpreted as"including but not limited to," the term "having" should be interpreted as "having atleast," the term "includes" should be interpreted as "includes but is not limited to,"etc.). It will be further understood by those within the art that if a specific number ofan introduced claim recitation is intended, such an intent will be explicitly recited inthe claim, and in the absence of such recitation no such intent is present. For example,as an aid to understanding, the following appended claims may contain usage of theintroductory phrases "at least one" and "one or more" to introduce claim recitations.However, the use of such phrases should not be construed to imply that the introductionof a claim recitation by the indefinite articles "a" or "an" limits any particulars claimcontaining such introduced claim recitation to inventions containing only one suchrecitation, even when the same claim includes the introductory phrases "one or more"or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and / or "an" shouldtypically be interpreted to mean "at least one" or "one or more"); the same holds truefor the use of definite articles used to introduce claim recitations. In addition, even if aspecific number of an introduced claim recitation is explicitly recited, those skilled inthe art will recognize that such recitation should typically be interpreted to mean atleast the recited number (e.g., the bare recitation of "two recitations," without othermodifiers, typically means at least two recitations, or two or more recitations).Furthermore, in those instances where a convention analogues to "at least one of A, Band C, etc." is used, in general such a construction is intended in the sense one havingskill in the art would understand the convention (e.g., "a system having at least one ofA, B and C" would include but not be limited to systems that have A alone, B alone, Calone, A and B together, A and C together, B and C together, and / or A, B, and Ctogether, etc.). In those instances where a convention analogous to "at least one of A,B, or C, etc." is used, in general such a construction is intended in the sense one havingskill in the art would understand the convention (e.g., "a system having at least one ofA, B, or C" would include but not be limited to systems that have A alone, B alone, Calone, A and B together, A and C together, B and C together, and / or A, B, and Ctogether, etc.). It will be further understood by those within the art that virtually anydisjunctive word and / or phrase presenting two or more alternative terms, whether inthe description, claims, or drawings, should be understood to contemplate thepossibilities of including one of the terms, either of the terms, or both terms. Forexample, the phrase "A or B" will be understood to include the possibilities of "A" or"B" or "A and B".

[0038] The above description does not provide specific details of manufactureor design of the various components. Those of skill in the art are familiar with suchdetails, and unless departures from those techniques are set out, techniques, known,related art or later developed designs and materials should be employed. Those in theart are capable of choosing suitable manufacturing and design details.

[0039] The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the present disclosure. It willbe appreciated that several of the above-disclosed and other features and functions, oralternatives thereof, may be combined into other systems or applications. Variouspresently unforeseen or unanticipated alternatives, modifications, variations, orimprovements therein may subsequently be made by those skilled in the art withoutdeparting from the scope of the present disclosure as encompassed by the followingclaims.

[0040] The claims, as originally presented and as they may be amended,encompass variations, alternatives, modifications, improvements, equivalents, andsubstantial equivalents of the embodiments and teachings disclosed herein, includingthose that are presently unforeseen or unappreciated, and that, for example, may arisefrom applicants / patentees and others.

[0041] While various aspects and embodiments have been disclosed herein,other aspects and embodiments will be apparent to those skilled in the art. The variousaspects and embodiments disclosed herein are for purposes of illustration and are notintended to be limiting, with the true scope and spirit being indicated by the followingclaims.

Claims

1. A device for automatic welding in wheel collar using CO2 welding comprising - Vertical adjustment means (1b) to adjust welding torch and wire feeder depending on the height of the wheel (2); - horizontal adjustment means (1c) comprising of horizontal screw rods for positioning of the torch and wire feeder depending on the width of the wheel (2); - Welding head mounted on guide with the help of hexagonal screw; - Structure to support and rotate the wheel; - Motorized Gear means (1d, 1e,1f, 1g, 1h, 1j, 1k, 1m, 1n); - Variable Frequency Drive (VFD) panel to control the speed of the motor.

2. The device for automatic welding as claimed in claim 1, wherein the Structure to support and rotate the wheel includes the support for horizontal movement of welding torch and wire feeder (1a), geared motor, drive roller(1g) and idler roller(1h), in which the drive roller speed is controlled by Variable Frequency Drive (VFD) through the control panel.

3. The device for automatic welding as claimed in claim 1 or 2, wherein CO2 welding power source is provided to carry out the welding process on the wheel (2) to increase the collar thickness, in which CO2 Welding Machine forms the welding power source that includes welding torch and wire feeder (1a) for welding on the job wheel (2) where the collar thickness is to be increased.

4. The device for automatic welding as claimed in claims 1-3, wherein CO2 Welding Torch and Wire feeder (1a) location on the job wheel (2) are adjusted with the help of the vertical adjustment (1b) depending on the height of the wheel and horizontal adjustment (1c) comprising of screw rod depending on the width of the wheel.

5. The device for automatic welding as claimed in claims 1-4, wherein the Coupling (1j) is a mechanical element to connect the main motor shaft with the gearbox shaft, in which the speed of the main motor shaft is adjusted by the variable frequency drive (VFD) depending on the required thickness of the welding on the job wheel (2).

6. The device for automatic welding as claimed in claims 1-5, wherein the Drive gear (1e) is a mechanical element that transfers power from the chain sprocket to the drive roller (1g) that is used to rotate the job wheel (2), in which the idler rollers (1d, 1h) support in the rotation of the job wheel.

7. The device for automatic welding as claimed in claims 1-6, wherein the Variable Frequency Drive (VFD) Panel is an electrical panel, that provides power supply to the Variable Frequency Drive (VFD) and has the adjustment mechanism for adjusting the speed of the Drive that helps in adjusting the job wheel speed.