GB2420515A

GB2420515A - A ram manufacturing system

Info

Publication number: GB2420515A
Application number: GB0425830A
Authority: GB
Inventors: Patrick Joseph Byrne; Patrick Byrne; Paschal Byrne; Nuala Byrne; Caroline Kelly; Lily Holmes; Nicola Byrne; Paul William Byrne
Original assignee: BURNSIDE RES
Current assignee: BURNSIDE RES
Priority date: 2004-11-24
Filing date: 2004-11-24
Publication date: 2006-05-31
Anticipated expiration: 2024-11-24
Also published as: GB2420515B; GB0425830D0

Abstract

A ram welding system 1 comprises a robotic welding head 2 and a cradle 3 which has a mounting 4 with at least two receiving chucks 5, 6 for ram connection pieces 8 and holders or tailstocks associated with the chucks 5, 6 respectively for pressing a ram cylinder or rod 12 against the connection piece 8. The ram welding station has two main areas, one (area A) for loading/unloading away from the welding head 2, and one (area B) for welding. In a first position (Fig. 3(a)) a first ram cylinder or rod mounted in a first holder and an associated first connection piece 8a mounted in the first chuck is presented to the welding head 2 at the welding area B. In this position a second ram cylinder or rod and associated second connection piece 8b are prepared for welding at the loading area A. The cradle 3 is rotatable to a second position (Fig. 3(b)) in which the first cylinder or ram with the first connection piece 8a welded thereto is presented for unloading to area A, and the second cylinder or rod and associated second connection piece 8b is presented to the welding head 2 in area B for welding. The system is highly efficient as it allows robotic welding to be exploited across a wide range of ram cylinders or rods and associated connection pieces.

Description

"A ram manufacturing system"

Introduction

The invention relates to a system for manufacturing rams, especially hydraulic rams.

There are a large number of steps involved in manufacturing rams in addition to the manufacture of cylinders and associated rods. Cylinders must he fitted with various connections, for example to provide inlet and outlet ports for hydraulic fluid, or ends for mounting the cylinder to fixtures. Similarly, rods are required to be provided with various connections such as end pieces and the like.

The attachment of such connections to cylinders and/or rods is time consuming and inefficient. Attempts have been make to automate some steps using robotic welding techniques. However, such techniques can only be used efficiently in the case of manufacture of a large numbers of single cylinders and rams of the same size and with *.. * uniform connections. **SI * I *I.*

There is therefore a need for a ram manufacturing system which can be used efficiently * across a range of different sized cylinders and rams and many different connections. a..

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* * This invention is directed towards providing such a ram manufacturing system. ** S *

Statements of invention

According to the invention there is provided a method for manufacturing a ram comprising the steps of: - (a) providing a plurality of ram cylinders and/or rods; (b) providing a plurality of connection pieces for mounting to the cylinders or rods; (c) providing a welding station comprising a robotic welding head and a cradle with at least two receiving chucks for ram connection pieces and holders associated with the chucks for holding a ram cylinder or rod to be welded to a connection piece; (d) providing a number of jaw sets suitable for a range of different connection pieces; (e) selecting a jaw set suitable for a first connection piece; (f) mounting the selected jaw set to a first one of the chucks; * *. * * * *** *

(g) mounting the first connection piece in position in the selected jaws;

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(h) mounting a first ram cylinder or rod associated with the selected first *IS * connection piece to a first one of the holders; ** * S.., (i) moving the first holder to present the first ram cylinder or rod to the first connection piece mounted in the first jaws, the connection piece being centred and squared when the first ram cylinder or rod is pressed against the connection piece; (j) repeating steps (e) to (i) for a second connection piece and associated second ram cylinder or rod, the second connection piece being mounted to a second chuck and the second cylinder or rod being mounted to a second holder; (k) moving the cradle to present the joint between the first connection piece and the first cylinder or rod to the welding head; (1) welding the joint between the first connection piece and ram cylinder or rod to form a first welded piece; (m) moving the cradle to present the first welded piece to an unloading station whilst presenting the joint between the second connection piece and the second cylinder or rod to the welding head; (n) releasing the first holder from the first welded piece; (o) removing the first welded piece from the first holder; * * a I *I I * :* (p) mounting a following connection piece and associated cylinder or rod to the first jaws and first holder by repeating steps (e) to (i); and * *.*I

III

* (q) repeating steps (n) to (p) to remove a second welded piece, and to present * * the following connection piece and associated cylinder or rod to the * II* *** * welding head.

In one embodiment the cradle is rotated for movement between the loading/unloading position and the welding position.

in one arrangement the chuck is movable to accommodate a range of connection pieces.

The jaws may be movable to accommodate a range of connection pieces.

In one embodiment the holder is linearly movable from the loading / unloading configuration to the engaged welding configuration.

The method may comprise aligning the cylinder or rod with the connection piece.

In one embodiment the connection pieces and the ram cylinders or rods in the first and second jaw sets and holders are the same.

Alternatively the connection pieces and the ram cylinders or rods in the first and second jaw sets and holders are different. In this case a connection piece and a cylinder in the first jaw set and first holder may form parts of the same ram as a connection piece and rod in the second jaw set and second holder.

The invention also provides a Eam welding station comprising: - a :.: * a robotic welding head; liii a S a...

a cradle having a mounting with at least two receiving chucks for ram connection a IS* * 20 pieces and holders associated with the chucks for holding a ram or cylinder to be

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* welded to a connection piece such that the connection piece is centred and * squared when a ram or cylinder is pressed against the connection piece; a.,. I. I * I *

the cradle being movable from a first position in which a first ram cylinder or rod mounted in a first holder and or associated first connection piece mounted in a first holder and an associated first connection piece mounted in the first chuck is presented to the welding head, and a second ram cylinder or rod and associated second connection piece are prepared for welding, to a second position in which the first cylinder or ram with the first connection piece welded thereto is presented for unloading, and the second cylinder or rod and associated second connection piece is presented to the welding head for welding.

In one embodiment each chuck has a pair of jaws which are adjustable relative to one another to accommodate a range of sizes of connection pieces. The jaws may be adjustable relative to the chuck. The jaws may be demountable from the associated chuck.

In one embodiment the cradle is rotatable for movement between the first and second positions.

In one embodiment each holder is movable from a loading configuration to receive a ram cylinder or rod and a welding configuration in which the cylinder or rod is aligned with the connection piece for welding. The holder may be linearly movable between the loading and welding configuration. In one embodiment the holder is movable by a lead screw. * S* * S S *** *

*: : : :* The invention also provides a ram manufacturing system.

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The ram manufacturing system may comprise a plurality of ram welding stations of the * invention.

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The system may comprise at least two sets of jaws for holding connection pieces of different size and/or configuration.

In one embodiment the system comprises three sets of jaws.

The invention also provides rams whenever manufactured by a method of the invention and/or using a ram welding station of the invention and/or a system of the invention.

Brief Description of the Drawings

The invention will be more clearly understood from the following description thereof given by many of example only, in which: - Fig. 1 is a general overview of a ram welding station according to the invention; Fig. 2 is a perspective view of part of the station of Fig. 1 with a ram assembly presented to a welding head for welding; Figs. 3 (a), 3 (b) and Fig. 4 are end views of mounting chucks of the welding station in different positions of use; Fig. 5 is a perspective view of a long jaw used into the system of the invention; Figs. 6 and 7 are perspective views of the jaw of Fig. 5; * ** * S S *e. * I.e.

** ,*** Fig. 8 is a top plan view of the jaw of Figs. 5 to 7;

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* 20 Fig. 9 is a perspective view of a short jaw used in the system of the invention; S..

Fig. 10 is a perspective view of a mid-length jaw used in the system of the S...

invention; Fig. 11 is an enlarged end view of one chuck of the welding station and associated mounting jaws; Fig. 12 is a perspective view of a chuck and jaw set in one configuration; Fig. 13 is a perspective view of the chuck and jaw set of Fig 12 in another configuration; Fig. 14 is a perspective view of another chuck and associated jaw set; Fig. 15 is a plan view of the chuck and jaw set of Fig. 14; Fig. 16 is a perspective view of a tailstock and dividing head in one configuration use; Fig. 17 is a perspective view of the tailstock and dividing head of Fig. 16 in another configuration use; Fig. 18 is a perspective view of a ram welding station with another configuration of jaws and holder, showing the chuck, steady rest and tailstock; Fig. 19 is a perspective view of a connection piece mounted in the jaws of the S...

station of Fig. 18; S.,...

Fig. 20 is a perspective view of a welded connection formed using the station of 5.

Fig. 18; S. * S...

Fig. 21 and 22. are perspective views illustrating the mounting of a rod to a holder of the station of Fig. 18; Fig. 23 is a perspective view on an enlarged scale of part of an end connection piece used in the station of Figs. 18 to 22; Fig. 24 is a perspective view of the connection piece part of Fig. 23 mounted in jaws of the station of Fig. 18; Fig. 25 is a perspective view of another part of the end connection piece of Figs. 18 to 24; Fig. 26 is a perspective view of another part of the end connection piece part of Fig. 25 mounted in position for welding; Fig. 27 is a perspective view of another connection piece and associated jaws; Fig. 28 is a perspective view of a further connection piece and associated jaws; Fig. 29 is a perspective view of another connection piece; and Fig. 30 is a perspective view of the connection piece of Fig. 29 mounted in associated jaws; * .. * S * S.. *

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* ** Detailed Description

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Referring to the drawings and initially to Figs. 1 to 4 thereof there is illustrated a a..

ram welding station 1 comprising a robotic welding head 2 and a cradle 3 which has a mounting 4 with at least two receiving chucks S...

5,6 for ram connection pieces 8 and holders or tailstocks 10,11 associated with the chucks 5,6 respectively for pressing a ram cylinder or rod 12 against the connection piece 8.

The ram welding station has two main areas, one (area A) for loading/unloading away from the welding head 2, and one (area B) for welding. Welding area B is screened from the loading / unloading area A. In a first position (Fig. 3(a)) a first ram cylinder or rod mounted in a first holder and an associated first connection piece 8a mounted in the first chuck 5a is presented to the welding head 2 at the welding area B. In this position a second ram cylinder or rod and associated second connection piece 8b are prepared for welding at the loading area A. The cradle 3 is movable, in this case rotatable to a second position (Fig. 3(b)) in which the first cylinder or ram with the first connection piece 8a welded thereto is presented for unloading to area A, and the second cylinder or rod and associated second connection piece 8b is presented to the welding head 2 in area B for welding. Fig. 4 illustrates an intermediate position.

Referring to Figs. 5 to 10 a wide range of different connection pieces can be accommodated using only three types of jaws namely long length jaws 13, short length jaws 14 and mid length jaws 15. Usually there will be two similar jaws used to accommodate a connection piece, however in some cases they may he mixed and matched. For example, in the configuration illustrated in Fig. 11 a : long length jaw 13 and a mid length jaw 15 are used together. In all cases the jaws define V-shaped recesses 20 and the arrangement is such that a connection piece 8 is automatically centred and squared when the tailstock 10, 11 presses the * 20 rod or ram cylinder 12 against the connection piece 8. When located in a chuck S..

* only the distance between the jaws is adjustable to ensure that the connection piece remains squared and centred in two planes. *5S* as. * . * * ..

The system optimises the welding operations because whilst one connection piece/ram is being welded a welded assembly is being unloaded and a following connection piece/ram is loaded. Thus, as soon as welding is complete another connection piece/ram is ready to be presented for welding. In one step the welded connection piece/ram is delivered from the welding area for unloading and the following connection piece/ram is presented to the welding head. The jaws and/or tailstock section can be easily changed to accommodate different connection pieces and ram cylinders/rods. Thus, the system is highly flexible and efficient.

Referring to Fig. 11 jaws 13, 15 are mounted to each chuck 5. The distance between the jaws is adjustable to accommodate a range of different connection pieces 8. The jaws 13, 15 are demountable from the associated chuck 5 to facilitate ease of replacement of the jaws to accommodate a wide range of different connection pieces at one station. The variation possible with a single pair of jaws will be readily apparent from Figs. 12 and 13. The jaws are slidably adjustable by way of a tongue and groove mounting 17 between the chuck 5 and the jaws. To adjust the distance between the jaws an allen key is inserted into a hole 26 in the chuck 5. On turning the key the jaws are slidable in the chuck. To remove the jaws the tongues of the jaws are disengaged from the associated groove in the chuck 5. The slidable movement of the jaws relative to the chuck 5 is further illustrated in Figs. 14 and 15.

Referring to Figs 16 and 17 each tailstock 10 is movable from a loading * ** S *** configuration (Fig. 16) to receive a ram cylinder or rod 12 and an engaged or welding configuration (Fig. 17) in which the cylinder 12 is aligned with and ****s* pressed against the connection piece 8. In this case the tailstock 10 is linearly **.

movable between the loading and engaged configurations by operation of a lead screw 30 and associated mounting arm or tailstock 31. In this case the holder may **S.

also incorporate an adjustable alignment arm or pointer 35 for setting the angular position of the ram/cylinder 12, for example to align with a connection piece 36 for a ram fluid inlet or outlet 39. The pointer system is used to facilitate correct rotation of the cylinder 12 to locate the hole 39 either at top dead centre or at any set angle. The system comprises a fixed sleeve 40 with a marker ledge 41 and a rotatable angular dividing head 42 to which the pointer 35 is mounted. The dividing head 42 is rotated to set the desired angle and is then fixed at this angle by a set screw 43. The cylinder 12 is then turned until the hole 39 or connection piece 36 is aligned with the pointer. In this configuration the cylinder 12 is then clamped ready for delivery to the welding head. It will be appreciated that for levy cylinders/rods 12 the system may incorporate an intermediate steady rest 55 as illustrated in Fig. 18.

In use, rams are manufactured by a method which comprises the steps of: (a) providing a plurality of ram cylinders and/or rods 12; (b) providing a plurality of connection pieces 8 for mounting to the cylinders or rods; (c) providing jaw 13, 14, 15 suitable for a range of different connection pieces 8; (d) selecting a jaw set suitable for a first connection piece 8; * S. a. a S.. a * SS S (e) mounting the selected jaw set to a first one of the chucks 5;

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* 20 (f) adjusting the chuck 5 and/or the jaws to accommodate the first connection *50 * piece 8; S...

* * (g) mounting the first connection piece 8 in the jaws; (h) mounting a first ram cylinder or rod 12 associated with the selected first connection piece 8 to a first one of the tailstock holders 10; (i) moving the first holder 10 to push the first ram cylinder or rod 12 against the first connection piece 8 mounted in the first jaws; (j) repeating steps (d) to (i) for a second connection piece and associated second ram cylinder or rod, the second connection piece being mounted to a second chuck and the second cylinder or rod being mounted to a second holder; (k) moving the cradle 3 to present the joint between the first connection piece 8 and the first cylinder or rod 12 to the welding head 2; (1) welding the joint between the first connection piece 8 and ram cylinder or rod 12; (m) moving the cradle 3 to present the first connection piece 8 with the first cylinder or rod 12 welded thereto to an unloading station whilst presenting the joint between the second connection piece and the second cylinder or rod to the welding head 2; :.:. (n) releasing the first holder 10 and first jaws 15, 16 from the first connection

.* piece 8 and first cylinder or rod 12 welded thereto;..DTD: I

a.... 20 (o) removing the first welded ram assembly from the first holder 10 and first jaws 15, 16; I. I

I a...

* a (p) mounting a following connection piece 8 and associated cylinder or rod 12 to the first jaws 15, 16 and first holder by repeating steps (d) to (j) ; and repeating steps (m) to (p) to remove the welded second connection piece and ram cylinder or rod welded thereto, and to present the following connection piece and associated cylinder or rod to the welding head.

- 13 - In Figs. 18 to 26 a ram rod 50 has an end connection 51 which requires an adapter 59 in addition to the mounting jaws. The intermediate jaw adapter 59 is clamped between the jaws 15, as illustrated. The intermediate jaw adapter 59 has a receiving slot into which the connection piece 51 is fitted and held in place during welding. As the rod 50 is relatively long there is an intermediate steady rest 55, 45 which is clamped onto the rod 50 as illustrated, intermediate the ends thereof.

Referring to Fig. 27 there is illustrated an arrangement of two of the larger jaws 13 for holding a relatively long connection piece 63. In another configuration illustrated in Fig. 28 the larger jaws 13 are arranged for supporting another narrower type of connection piece 66.

Referring to Figs. 29 and 30 the larger jaws 13 are shown in use with another temporary adapter in the form of a male part 75 for insertion into a hole 76 in a U block connection piece 77. The male adapter 75 is centred by the jaws 13 and it in turn centers the U block connection piece 77. S...

The invention provides a ram manufacturing apparatus and method which is highly efficient as it allows robotic welding techniques to be exploited across a * 20 wide range of ram cylinders or rods and associated connection pieces. In S..

particular, the system facilitates ease of change-over from one ram cylinder or rod S to another and from one connection piece to another. A wide range of different rams can be manufactured at a single robotic welding station.

The invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims

Claims 1. A method for manufacturing a ram comprising the steps of: - (a)

providing a plurality of ram cylinders and/or rods; (b) providing a plurality of connection pieces for mounting to the cylinders or rods; (c) providing a welding station comprising a robotic welding head and a cradle with at least two receiving chucks for ram connection pieces and holders associated with the chucks for holding a ram cylinder or rod to he welded to a connection piece; (d) providing a number of jaw sets suitable for a range of different connection pieces; * ** * * S *5S S *S55 I,.... (e) selecting ajaw set suitable for a first connection piece; S.....

(f) mounting the selected jaw set to a first one of the chucks; *1s

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(g) mounting the first connection piece in position in the selected jaws; S. * * *1 S ** (h) mounting a first ram cylinder or rod associated with the selected first connection piece to a first one of the holders; (i) moving the first holder to present the first ram cylinder or rod to the first connection piece mounted in the first jaws, the connection piece being centred and squared when the first ram cylinder or rod is pressed against the connection piece; - 15 - (j) repeating steps (e) to (i) for a second connection piece and associated second ram cylinder or rod, the second connection piece being mounted to a second chuck and the second cylinder or rod being mounted to a second holder; (k) moving the cradle to present the joint between the first connection piece and the first cylinder or rod to the welding head; (1) welding the joint between the first connection piece and ram cylinder or rod to form a first welded piece; (m) moving the cradle to present the first welded piece to an unloading station whilst presenting the joint between the second connection piece and the second cylinder or rod to the welding head; : (n) releasing the first holder from the first welded piece; S... * S S.. .

(o) removing the first welded piece from the first holder; S.....

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(p) mounting a following connection piece and associated cylinder or rod to * . the first jaws and first holder by repeating steps (e) to (i); and

S * S *

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(q) repeating steps (n) to (p) to remove a second welded piece, and to present the following connection piece and associated cylinder or rod to the welding head.
2. A method as claimed in claim 1 wherein the cradle is rotated for movement between the loading/unloading position and the welding position.
3. A method as claimed in claim I or 2 wherein the chuck is movable to accommodate a range of connection pieces.
4. A method as claimed in any of claims 1 to 3 wherein the jaws are movable to accommodate a range of connection pieces.
5. A method as claimed in any of claims 1 to 4 wherein the holder is linearly movable from the loading / unloading configuration to the engaged welding configuration.
6. A method as claimed in any preceding claim comprising aligning the cylinder or rod with the connection piece.
7. A method as claimed in any preceding claim wherein the connection pieces and the ram cylinders or rods in the first and second jaw sets and holders are the same.

:. : :
8. A method as claimed in any of claims 1 to 6 wherein the connection pieces and S...

the ram cylinders or rods in the first and second jaw sets and holders are different.

S.....
9. A method as claimed in claim 8 wherein a connection piece and a cylinder in the first jaw set and first holder form parts of the same ram as a connection piece and * . rod in the second jaw set and second holder. I. *

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10. A method for manufacturing a ram substantially as hereinbefore described with reference to the accompanying drawings.
11. A ram welding station comprising: - a robotic welding head; - 17 - a cradle having a mounting with at least two receiving chucks for ram connection pieces and holders associated with the chucks for holding a ram or cylinder to be welded to a connection piece such that the connection piece is centred and squared when a ram or cylinder is pressed against the connection piece; the cradle being movable from a first position in which a first ram cylinder or rod mounted in a first holder and or associated first connection piece mounted in a first holder and an associated first connection piece mounted in the first chuck is presented to the welding head, and a second ram cylinder or rod and associated second connection piece are prepared for welding, to a second position in which the first cylinder or ram with the first connection piece welded thereto is presented for unloading, and the second cylinder or rod and associated second connection piece is presented to the welding head for welding.
12. A ram welding station as claimed in claim 11 wherein each chuck has a pair of * jaws which are adjustable relative to one another to accommodate a range of sizes of connection pieces. * 20 *.*
13. A ram welding station as claimed in claim 12 wherein the jaws are adjustable relative to the chuck.

* * *,. I. * **
14. A ram welding station as claimed in any of claims 11 to 13 wherein the jaws are demountable from the associated chuck.
15. A ram welding station as claimed in any of claims 11 to 14 wherein the cradle is rotatable for movement between the first and second positions.

- 18 -
16. A ram welding station as claimed in any of claims 11 to 15 wherein each holder is movable from a loading configuration to receive a ram cylinder or rod and a welding configuration in which the cylinder or rod is aligned with the connection piece for welding.
17. A ram welding station as claimed in any of claims 11 to 16 wherein the holder is linearly movable between the loading and welding configuration.
18. A ram welding station as claimed in claim 17 wherein the holder is movable by a lead screw.
19. A ram welding station substantially as hereinbefore described with reference to the accompanying drawings.
20. A ram manufacturing system comprising a ram welding station as claimed in any of claims 11 to 19. S ? * S S s*a,
21. A ram manufacturing system comprising a plurality of ram welding stations as claimed in any of claims 11 to 19.

- S.
22. A system as claimed in claim 20 or 21 comprising at least two sets of jaws for holding connection pieces of different size and/or configuration. I... S. * 4I

*
23. A s5'stem as claimed in claim 22 comprising three sets of jaws.
24. Rams whenever manufactured by a method as claimed in any of claims 1 to 10 and/or using a station as claimed in any of claims 11 to 19 or a system as claimed in any of claims 20 to 23.