JP2005103621A - Method for manufacturing segmental tee for continuous water supplying drill machining - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a segmental tee for continuous water supplying drill machining with which cost of a mold can be made to low by manufacturing many kinds of castings with a few molds. <P>SOLUTION: This manufacturing method is performed, with which foamed resin-made original molds 30A, 30B are made from metal-made base molds 10A, 10B and castings 21A, 21B are manufactured by pouring molten metal into the original mold portions. Then, the castings 21A, 21B are a branch side body case 21 integrally forming a valve box part 72 of a gate valve 70 for branching, with the branching part 27 of the segmental tee 2. As the castings 21A, 21B, the first casting 21A for small bore, in which the nominal diameter of the gate valve is small, and the second casting 21B for large bore, in which the bore ratio of the gate valve is larger than that for the small bore, are manufactured. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a split T-shaped pipe used in a continuous water drilling method performed when a branch pipe is attached to an existing pipe such as a water pipe.

2. Description of the Related Art Conventionally, a method of drilling a part of an existing pipe under constant water using a drilling machine equipped with a hole saw is known (for example, see Patent Document 1).
JP 2002-321109 A

  The split T-shaped pipe used in such a drilling method requires a plurality of divided cases attached to the existing pipe and a gate valve for perpetual water drilling. In recent years, an integrated type in which the valve box of the gate valve is molded integrally with one of the divided cases has been adopted. This integrated type has the merit that the seal portion can be reduced. On the other hand, in this drilling work, a branch having a nominal diameter of 75 mm to 1500 mm or less is set for the existing pipe type having a nominal diameter of 75 mm to 1500 mm. Therefore, it is necessary to prepare a large number of castings and molds in the integrated type in which the valve box part is integrally formed at the branch part.

  Therefore, this invention is providing the manufacturing method of the split T-shaped pipe for the continuous water branch drilling which can make the cost of a metal mold | die cheap by producing | generating many types of castings with few metal mold | dies. .

  The manufacturing method of the present invention for achieving the above object is to produce a casting by creating a foamed resin prototype from a metal mother mold and injecting a molten metal into the prototype portion. A branch-side body case in which the valve box portion of the branch gate valve is integrally formed with the split portion of the split T-shaped pipe. As the casting, for the small diameter, the nominal diameter of the gate valve is smaller than the nominal diameter of the existing pipe. It is assumed that the first casting and the second casting for the large diameter, in which the ratio of the nominal diameter of the gate valve to the nominal diameter of the existing pipe is larger than that for the small diameter.

  In the first invention, the first and second valve boxes according to the diameter of the gate valve are set in accordance with the diameter of the gate valve, regardless of whether the diameter is the same or different. A part prototype is created, and the first or second valve box prototype is selectively joined to the one type of branch prototype to produce a casting prototype.

  In the second aspect of the invention, the valve box prototype is set to one or more types for each nominal diameter of the existing pipe regardless of the same diameter or different diameter, and the first and second branches according to the diameter of the gate valve A part prototype is created, and the first or second branch prototype is selectively joined to the one type of valve box prototype to produce a casting prototype.

  According to the first invention, according to the second invention, since the type of the valve box part prototype or the branch part prototype is reduced, the kind of the master mold (mold) for generating the same is also reduced. Therefore, the initial cost can be reduced and the space efficiency for accommodating the mother die is also improved.

Embodiments of the present invention will be described below with reference to the drawings.
First, prior to describing the manufacturing method of the present invention, the structure and usage of a casting manufactured according to the present invention will be described.

  As shown in FIG. 1, the split T-shaped tube 2 surrounds the existing tube 1 in an airtight state. The split T-shaped pipe 2 includes first and second divided cases 21 and 22 that are divided in the circumferential direction R of the existing pipe 1. Both split cases 21 and 22 are cases that are externally fitted to the existing pipe 1 from both sides in the radial direction C of the existing pipe 1, and are assembled by fastening the flange portion 20 with the assembly bolt 61. Yes.

  Each of the divided cases 21 and 22 includes a cover 29 that is curved along the outer peripheral surface 13 of the existing pipe 1. As shown in FIGS. 2 (a) and 2 (b), both ends of the pipe portion L (FIG. 2) of the existing pipe 1 in the flange portions 20 and the cover portions 29 of the divided cases 21 and 22 are respectively shown. A groove-shaped packing mounting portion 50 is formed. A rubber packing 26 of FIG. 1 is mounted on the packing mounting portion 50, and between the existing pipe 1 and the split T-shaped pipe 2, or between the first split case (branch side body case) 21 and the second split case 22. The space between is sealed.

  The first divided case 21 is integrally provided with a cylindrical portion 27, the cover portion 29, and a chip pool 28. The cylindrical portion 27 is formed so as to project in a branched shape toward the outside in the pipe radial direction C of the existing pipe 1. As shown in FIG. 1, a branch gate valve 70 is provided in the cylindrical portion 27. The punching machine 3 is attached to the flange portion 71 of the cylindrical portion 27, and the hole saw 4 is fed in the radial direction C of the existing tube 1 through the cylindrical portion 27, so that the existing tube 1 is An opening 11 is drilled.

  A valve box portion 72 and a flange portion 71 of the branch gate valve 70 are integrally formed in the cylindrical portion 27 of the first divided case 21. A valve lid 73 is mounted above the valve box portion 72, and a valve body 74 is accommodated inside the valve box portion 72 and the valve lid 73.

Next, each step of the drilling method will be described.
Attachment process First, the split T-shaped tube 2 is attached in a state where fluid (water) is flowing in the existing tube 1 of FIG. After this attachment, the operator assembles both split cases 21 and 22 with the assembly bolt 61. At this time, a set screw is screwed into the female screw 65 formed in each of the divided cases 21 and 22 shown in FIGS. Thereafter, the operator attaches the drilling machine 3 to the flange portion 71 of the cylindrical portion 27 of the sealed case 2. Thus, the sealed case 2 surrounds a part of the existing pipe 1 in an airtight state.

Drilling Step After the mounting step, the operator operates the punching machine 3 to feed the hole saw 4 through the cylindrical portion 27 to a position approaching the side of the existing pipe 1 as shown in FIG. Thereafter, when the operator drives a prime mover (not shown), the hole saw 4 rotates and a cutting motion for cutting the existing pipe 1 is started. When the operator operates the drilling machine 3 and feeds the hole saw 4 from the substantially horizontal direction toward the existing pipe 1 while performing the cutting motion, a part of the pipe wall of the existing pipe 1 is cut off. Then, the opening 11 shown in FIG. 3 is drilled.

Next, a mold and the like prepared prior to the description of the manufacturing method of the first split case (branch side main body case) 21 of the split T-shaped tube 2 will be described.
The said 1st division | segmentation case 21 grade | etc., Consists of castings, such as FCD (ductile cast iron). In this casting, the foamed resin prototypes 30A and 30B shown in FIG. 6 are prepared from the metal masters 10A and 10B shown in FIG. 4, and molten metal is poured into the prototype parts to produce castings 21A and 21B. The castings 21 </ b> A and 21 </ b> B are branch-side body cases 21 in which the valve box portion 72 of the branch gate valve 70 of FIG. 1 is integrally formed with the branch portion 27 of the split T-tube 2.

As described above, the sizes of the castings 21A and 21B in FIG. 6 exist as many as the combinations of the nominal diameter and the branch diameter of the existing pipe 1.
As the castings 21 </ b> A and 21 </ b> B, the first casting 21 </ b> A for a different diameter (for a small diameter), which has a smaller nominal diameter than the existing pipe 1, and the existing pipe 1 and the gate valve 70 are approximately. A method of manufacturing the second casting 21B for the same diameter (for large diameter) that is the same diameter will be described.

  First, a not-shown branch part mother die, a valve box mother die 10A, 10B in FIG. 4, and an attachment die 15 in FIG. 4B are prepared. These mother molds are molds.

  The matrix of the branch portion (not shown) is for generating the branch portion prototypes 31 and 33 made of foamed resin shown in FIGS. 5A and 5C, and is prepared for each nominal diameter of the existing pipe 1. In addition, since the branching part mother block is configured by a conventional method, the illustration thereof is omitted.

  4A is used for generating the first and second valve box part prototypes 32 and 34 made of foamed resin shown in FIGS. 5B and 5D. It is prepared for each nominal diameter of the gate valve 70.

The attachment die 15 in FIG. 4 (b) is mounted as shown in FIG. 4 (b) on the base 10A of the valve box portion in FIG. 4 (a) in the case of the same diameter, and the attachment die 15 in FIG. This is for connecting a portion 35 between the branch portion 33 and the second valve box portion 34 of FIG.
4A includes a fixed mold 14 and first, second, and third sliding molds 11, 12, and 13. As shown in FIG. The attachment mold 15 is attached to the first sliding mold 11.

  When the prototype 30A for different diameters in FIG. 6 (a) is created, the branch portion prototype 31 in FIG. 5 (a) made of foamed resin is generated by injection using a master block of a branch portion (not shown). On the other hand, the first valve box prototype 32 made of the foamed resin shown in FIG. 5B is generated by injection using the base mold 10A of the valve box shown in FIG. 4A. A first valve box portion prototype 32 is joined to the branch portion prototype 31 generated in this manner to create a prototype 30A for different diameters in FIG.

  In the joining, the branch part prototype 31 and the first valve box prototype 32 are bonded with an adhesive, and a paper tape is wound around the joint 35 between the two. After the joining, a prototype made of liquid is applied to the prototype 30A and dried to produce the prototype 30A. Thereafter, according to a conventional method, the original mold 30A is loaded into a metal frame (not shown), and after sand is poured, the molten metal is poured into the original mold 30A. Thereby, the foamed resin in the portion of the original mold 30A melts and flows, and a casting 21A having the same shape as the original mold 30A is obtained.

  When the prototype 30B for the same diameter of FIG. 6B is created, the branch portion prototype 33 of FIG. 5C made of foamed resin is generated by injection using a master portion of a branch portion (not shown). On the other hand, the attachment die 15 of FIG. 4B is mounted on the die 10A of the valve box portion of FIG. 4A, and the foamed resin of FIG. 5D is made by injection using the die 10B with the attachment. The second valve box prototype 34 is generated. By attaching the attachment die 15, the taper continuous portion 36 of FIG. 4A is filled with the attachment die 15, and the master 30 </ b> B without the taper continuous portion 36 is obtained. The second valve box prototype 34 shown in FIG. 5 (d) is joined to the branch prototype 33 shown in FIG. 5 (c) thus produced, thereby producing a prototype 30B for the same diameter shown in FIG. 6 (b).

  In addition, the method for obtaining the casting 30B for the same diameter from the prototype 30B is the same as that for the different diameter, and detailed description thereof is omitted.

  5 (a) and 5 (c), the branch portion prototypes 31 and 33 are provided with the cylindrical portion 27 having the same diameter which is the maximum of the branch diameter, and the first valve for different diameters. The box prototype 32 is provided with a taper continuous portion 36 for reducing the diameter, while the second valve box prototype 34 for the same diameter is a taper continuous portion of the first valve box prototype 32. The shape is set such that 36 is removed. In generating the first and second valve box part prototypes 32 and 34, the attachment mold 15 of FIG. 4B is mounted on the valve box part mother die 10A for different diameters of FIG. 4A. The portion corresponding to the tapered connecting portion 36 is filled, and the valve box base die 10B for the same diameter is generated. Therefore, since the number of mother dies 10A and 10B which are dies is reduced, the initial cost is reduced and the space efficiency for accommodating the dies is also improved.

  In the first embodiment, the first and second valve box part prototypes 32 and 34 of FIG. 5 are generated. However, in the present invention, the first or second branch part is provided for one valve box part prototype. The prototypes may be selectively joined. An example of this will be described with reference to FIG.

  When creating a prototype for different diameters, the first branch part prototype 131 of FIG. 7A is generated from the master part of the branch part (not shown), and the master part of the valve box part is used as shown in FIG. 7B. A valve box prototype 132 is generated, and the valve box prototype 132 is joined to the first branch prototype 131 to create a prototype for different diameters.

  On the other hand, when creating the prototype for the same diameter, the valve box prototype of FIG. 7 (d) is generated from the master of the valve casing (not shown), and the attachment mold is attached to the master of the branching section. The second branch part prototype 133 of FIG. 7 (c) is generated from the mother mold with the attachment, and the second branch part prototype 133 is joined to the valve box part prototype 132 to create a prototype for the same diameter. To do.

  In this case, the attachment type has a shape corresponding to the tapered connecting portion 136 of FIG. 7A, and is attached to the master die of the branch portion in the case of the same diameter. A space is connected. The tapered connecting portion 136 is formed integrally with the cylindrical portion 27 of the branch portion prototype 131.

  In the embodiment, the attachment mold 15 of FIG. 4B is attached to the first sliding mold 11 of FIG. 4A. In the present invention, the first sliding mold of FIG. 4A is used. Instead of attaching / detaching the attachment mold 15 portion of FIG. 4B to FIG. 11, an attachment mold in which the attachment mold 15 portion is integrally formed may be a sliding type. That is, the prototypes 30A and 30B may be generated by exchanging the first sliding mold in FIG. 4A with the sliding mold in FIG. 4B.

  By the way, in each of the first and second embodiments, the case of the same diameter and the different diameter has been described, but the present invention can also be applied to cases where the different diameters have different branch diameters. That is, as a casting, the first casting for a small diameter whose nominal diameter of the gate valve is smaller than the nominal diameter of the existing pipe, and the ratio of the nominal diameter of the gate valve to the nominal diameter of the existing pipe is larger than that for the small diameter. It can also be applied to the case of producing two castings. For example, for the existing pipe of φ200, the gate valve is provided with a first split case that can also use φ100 or φ75, and the φ100 gate valve is not provided with the taper continuous portion, but the taper continuous portion is provided on the φ75 gate valve. May be provided.

As described above, the preferred embodiments have been described with reference to the drawings. However, those skilled in the art will readily understand various changes and modifications within the obvious scope by looking at the present specification.
For example, the sealed case may be divided into three or four in the circumferential direction.
Further, the working gate valve is not limited to the soft seal valve, and a known gate valve can be adopted. Further, the sealed case and the work gate valve may be separate from each other. Moreover, it may replace with the flange part 71 and may employ | adopt a mechanical coupling for water supply.
In addition to water supply, it can also be applied to drilling of liquids such as petroleum.
Accordingly, such changes and modifications are to be construed as within the scope of the present invention as defined by the claims.

It is the side view which carried out the partial cross section which shows the attachment process of the continuous water construction method concerning the Example of this invention. (A) And (b) is a top view of the 1st and 2nd division | segmentation case respectively seen from the inner side. It is the side view which carried out the partial cross section which shows the state after completion of perforation. It is a schematic sectional drawing which shows the mother die concerning 1st Example. It is a schematic sectional drawing which shows the original model before joining. It is a schematic side view which shows the original model and casting after joining. It is sectional drawing which shows the original pattern before joining concerning Example 2. FIG.

Explanation of symbols

1: Existing pipes 10A, 10B: Metal master mold 2: Split T-shaped pipe 27: Branch part 21A, 21B: Casting 30A, 10B: Molded resin mold 70: Branch gate valve 72: Valve box part 131: First branch portion prototype 133: Second branch portion prototype 132: Valve box portion prototype

Claims (4)

In the manufacturing method of creating a casting made by injecting molten metal into a prototype made of foam resin from a metal mother mold,
The casting is a branch-side main body case in which the valve box portion of the branch gate valve is formed integrally with the split portion of the split T-tube,
As the casting, the ratio of the nominal diameter of the gate valve to the nominal diameter of the existing pipe is larger than that of the first casting for the small diameter, which is smaller than the nominal diameter of the existing pipe, and the nominal diameter of the existing pipe. A manufacturing method for manufacturing a second casting for a large diameter,
Prepare a master block for the branch for each nominal diameter of the existing pipe,
Prepare a matrix for the valve box for each nominal diameter of the gate valve,
In the case of the large diameter, it is mounted on a master block of the valve box part, and an attachment mold for connecting between the branch part and the valve box part is prepared,
When creating the prototype for the small diameter, a branch part prototype is generated from the master part of the branch part, a first valve box part prototype is generated from the master part of the valve box part, and the branch part prototype is generated. The first valve box prototype is joined to the small diameter prototype,
When creating the prototype for the large diameter, a branch part prototype is generated from the master part of the branch part, the attachment mold is attached to the master part of the valve box part, and the master part with the attachment is used. 2 valve box part prototype is created, and the second valve box part prototype is joined to the branch part prototype to create the prototype for the large diameter,
A method of manufacturing a split T-shaped tube for continuous water branch drilling. In Claim 1, the branch part includes a cover part that covers a part of the existing pipe along the outer peripheral surface of the existing pipe, and a cylindrical part that protrudes from the cover part and continues to the valve box,
The first valve box part prototype includes a taper continuous part for reducing the diameter from the cylindrical part,
The second valve box part prototype does not have the tapered connecting part,
The said attachment type | mold is set to the shape corresponded to the said connection part, The manufacturing method of the split T-shaped pipe for the continuous water branch perforation which prevented the molten resin from entering into this connection part. In the manufacturing method of creating a casting made by injecting molten metal into a prototype made of foam resin from a metal mother mold,
The casting is a branch-side main body case in which the valve box portion of the branch gate valve is formed integrally with the split portion of the split T-tube,
As the casting, the ratio of the nominal diameter of the gate valve to the nominal diameter of the existing pipe is smaller than the nominal diameter of the existing pipe and the first casting for the small diameter whose nominal diameter of the gate valve is smaller than the nominal diameter of the existing pipe. A manufacturing method for manufacturing a second large casting for a large diameter,
Prepare a master block for the branch for each nominal diameter of the existing pipe,
Prepare a matrix for the valve box for each nominal diameter of the gate valve,
In the case of the large diameter, it is attached to the master part of the branch part, and an attachment mold for connecting between the branch part and the valve box part is prepared,
When creating the prototype for the small diameter, a first branch part prototype is generated from the master part of the branch part, a valve box part prototype is generated from the master part of the valve box part, and the first Join the first valve box prototype to the branch prototype to create the prototype for the small diameter,
When creating a prototype for the large diameter, generate a valve box prototype from the master of the valve box, and attach the attachment mold to the master of the branch, and from the master with the attachment Generating a second branch portion prototype, and joining the valve box portion prototype to the second branch portion prototype to create the prototype for the large diameter;
A method of manufacturing a split T-shaped tube for continuous water branch drilling. In claim 3, the branch portion includes a cover portion that covers a part of the existing tube along the outer peripheral surface of the existing tube, and a cylindrical portion that protrudes from the cover portion and continues to the valve box,
The first branch portion prototype includes a taper continuous portion for reducing the diameter from the cylindrical portion and continuing to the valve box portion prototype,
The second branch portion prototype does not have the tapered connecting portion,
The said attachment type | mold is set to the shape corresponded to the said connection part, The manufacturing method of the split T-shaped pipe for the continuous water branch perforation which prevented the molten resin from entering into this connection part.

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