Improvements in Apparatus for Making Tubes of Polygonal Section such as Headers for Sectional Steam Generators.
Year: 1893

page_text: CUMI LEIE DIDITATION.
[Communicated from abroad by THE BABCOCK & WILCOX COMPANY, of New
York, in the United States of America, Steam Boiler Manufacturers.]
Improvements in Apparatus for Making Tubes of Polygonal Section
such as Headers for Sectional Steam Generators.
I, WALLACE FAIRWEATHER, C.E., of 62 Saint Vincent Street in the City of
Glasgow, Chartered Patent Agent, do hereby declare the nature of this invention
and in what manner the same is to be performed as communicated to me to be
particularly described and ascertained in and by the following statement :-
This invention relates to apparatus for making end pieces for tubes of polygonal
section such as are designed for use as headers in sectional steam generators and
for placing and welding such end pieces in the tubes or headers.
The invention comprises (1) a machine designed for cutting end pieces for headers
for sectional steam boilers or other metallic boxes which are made from a tube of
rectangular or other cross sectional form, and having a die press adapted both for
cutting the external margin of the plate and also a tube hole or other aperture
therethrough the apertures being performed independently at different times, but
without material change in the parts of the machine, (2) apparatus adapted to
automatically insert the end pieces of the tube and clinch the same in position
preparatory for welding in a separate machine, and, (3) apparatus adapted to
automatically weld the end piece to the sides of the box or tube, and also to trim
the edges or margins simultaneously with the operation of welding.
Referring to the accompanying drawings,
Figure 1 is a side elevation of the machine for cutting or making end pieces for
headers.
Figure 2 is a front sectional elevation taken on the line x-x, Figure 1.
Figure 3, a horizontal section on the line y-y, Figure 2.
Figure 4, a sectional side elevation taken on the line -z, Figure 2.
Figure 5, a detail plan view of the abutment sleeve for the shaping die.
Figure 6 a detail view and cross sectional views respectively of the metal
shaping die.
Figure 7 a detail view showing a plan of the intercepting block for determining
the advanced or retracted position of the metal shaping die.
Figures 8 and 9 detail views showing in vertical section various positions of
the dies.
Figure 10 a top plan view of the support for the abutment of the metal shaping
die, forming also the channel for introducing and removing the work.
Figure 11
shaping die.
a plan and cross sectional view respectively of the female
Figure 12 a plan view of the support for the same, showing also the female
perforating die therein.
Figure 13 a plan and end view respectively of the receptacle for the piece in
Figure 12.
Figure 14 is an elevation of part of the header plant taken on the line x-x,
Figure 15, wherein the heating and welding fires and the end placing and end
welding and other machines are located in proximity and the work suspended from
a common crane during the successive operations. Figure 15 a plan view of the
same.
Figure 16 a sectional side elevation of the end placing machine.

page_text: line y-y, Figure 16.
Figure 17 a plan view of the multiple compressing cylinder.
Figure 17 a detail view showing the draw-box in section.
Figure 18 is a sectional elevation of the machine taken on the line y-y,
Figure 16, showing a preparatory position.
Figure 19 a similar sectional elevation showing the final position of compression.
Figure 20 is a side elevation partly in section on the line e-x, Figure 21, of the
welding machine and crane.
Figure 21 a front elevation partly in section on the line y-y, Figure 20, of the
welding machine.
Figure 22 a detached view partly in section showing the lower end of the header
preparatory to welding.
Figure 23 is an enlarged sectional elevation taken on the line y-y, Figure 24,
showing the preparatory position of insertion of the header into the machine,
and also illustrating certain modifications.
Figure 24 a sectional elevation taken on the line -, Figure 23, also
illustrating the preparatory position of operation.
Figures 25, 26 and 27 are sectional views similar to Figure 24, illustrating
consecutively the several remaining positions of operation.
Figure 28 is a horizontal section taken on the line -, Figure 23.
Figure 29 is a plan view of the welding rolls and Figure 30 a horizontal section
taken on the line '-', Figure 26.
Figures 31, 32 and 33 are detail views illustrating a modified shear plate and
successive operations of the same, and, Figures 34, 35 and 36, sectional elevations
illustrating the operation of the machine employing such modified plate.
Figure 37 is a detail view showing the draw-box in section.
Referring to the drawings Figures 1 to 13 showing the apparatus for cutting
or making the end pieces, the upper or elevated stationary head A. of the
machine is supported by columns B, B upon the bed C, which contains the
hydraulic ram D, for actuating the dies, the latter being retracted by means of
auxiliary rams 3, 3, subsequent to each operation, a suitable apparatus being
provided for controlling the water, indicated at E, Figures 2 and 3. Upon the
head H, of the ram D is placed a die holder 5, which contains a die support 6,
and the female perforating die 7, these parts being held in place and to the
collar 10, by means of the bolts a, a Figure 2, which when removed allows the
holder 6 to be removed as shown in the dotted lines, Figure 4. Upon
the holder 5 rests the holder 8, containing the female shaping die 9, and upon
the holders 5 and 8, thus superimposed, is bolted the guiding collar 10 which
binds the aforesaid parts together, as shown in Figure 1, and which embraces
and slides upon the upper die 12. 11, is a male perforating die, and 12, the
male shaping die adapted to fit and co-operate with the dies 7 and 9 respectively.
In the illustration the dies 11 and 7 have circular steel cutting edges, while
the dies 12 and 9 of steel, present a rectangular contour. The die 11 is com-
posed of a separate block retained on the stationary head 15, by means of a
split spring nipple, as shown in Figure 2, which expands into the concaved hole
through the said block 11, when the latter is inserted. The sleeve 16, upon which
the confining collar slides, also serves as an abutment for the die 12, and according
as such die, 12 is intended to be placed in an active or inactive position, such
sleeve 16, is advanced or retracted accordingly. In its advanced position the
sleeve is supported as shown in Figure 2, by means of the intercepting piece 17,
shown separately in Figure 7. The bottom of the confining sleeve 10, is provided
with a through channel 20, for the introduction of the plate 21.
In the operation of the machine, the plate 21 is inserted in position through the
channel 20, as shown at Figure 4. The ram D, is advanced, carrying with it the
head 4, the interposed lower dies and the confining sleeve 10, moving them upward
over the annular abutment 16 of the die 12. The edges of the work are thus

page_text: sheared or trimmed off between the dies 9 and 12, the scrap lying in the channel 20,
while the plate passes through the die 9 into the cavity 22, as shown in Figure 8,
from whence it may be subsequently removed, if desired, without further operation.
To perforate the plate 21, if desired the ram D is partially retracted and the
support 17 of the abutment 16 is removed, and the ram again advanced. The
die 12 and the abutment will then move idly the perforating die 11 remaining fixed
and thereby the lower perforating die telescoping it, will perforate the plate held
in the cavity 22, as shown in Figure 9.
Referring to the drawings of the apparatus for placing the end pieces into the
headers in Figures 14 and 15, A, represents the heating furnace, B the end placing
machine, C the welding fire, and D, the end welding machine, the header being
passed from one to another of said appliances in the order named. E, represents a
suitable crane by which the header F, is suspended end wise and elevated or lowered
and transferred about during the several operations. The end welding machine
referred to is hereinafter fully described.
3, Figures 16 to 19 inclusive, represents the end placing block supported on the
bed 5, and operated on vertically movable rods 4, extending through the bottom of
the bed.
The block 3, may be raised when free from pressure, to the position shown in
Figure 18 for introducing the end piece in position by depression of the handle 6,
connected by a lever as indicated. 8, represents the end piece which is placed by means
of the machine in the end of the corrugated header F. 10, Figure 16, is a hydraulic
cylinder provided with an inserting ram 11, and a retracting plunger 12, and head 13,
adapted for forcing the header down over the block 3. 15, represents a stop collar
which is functionally a stop to limit the downward stroke given to the header F,
thereby determining the distance of insertion of the end piece 8. The draw-box 15
rests at the termination of its stroke on the bearing blocks 16. The stop-collar 15,
as shown in Figure 17B is composed of the stationary piece 17, and movable
block 18, keyed into the flanks of the piece 17, by means of the key 19 and the
binding faces of the parts 17 and 18, correspond to the serpentine contour of the
header F, and are thus adapted for secure attachment.
The frame 20, supporting the cylinder 10, is swivelled at 21 so that it may be
thrown out of vertical alignment with the header F, after the hydraulic head 13,
has been retracted, and the angular motion of the frame 20, which is indicated by
dotted lines in Figure 16, is regulated by the same rod 22 and block 23, adapted to
be moved or secured in the ways 24, at different positions.
30, represents four hydraulic rams in the multiple cylinder in the bed 5, which
are adapted to advance upon the four respective sides of the rectangular tube F;
suitable water connections being provided. The faces of the rams 30, are inclined
so that when compressed they partially upset the flanges of the header or box
inward and clinch the end piece after it has been inserted.
The operation of the end placing apparatus is as follows:-
The header F suspended on the crane E with its draw-box 15 attached, is
brought from the heating fires A, to the end placing machine B, and the frame 20
being retired to its angular position shown at Figure 16, the header with its end
heated is dropped over the end piece 8 which has been placed upon the block 3, as
in Figure 18. The whole is then lowered into the machine until the block 3, rests
upon the base 5, as indicated in Figures 16 and 17; and the cylinder 10 then
brought into vertical alignment and pressure applied to the plunger 11, forcing the
draw-box 15 hard down on to the bearing blocks 16, as shown in Figures 16 and 17.
While in this position, the hydraulic pressure is applied to the four radially moving
rams 30, as shown at Fig. 19, and the inclined faces of these rams force the four
sides of the header hard on to the end piece 8, which has been pushed into the same,
thus clinching it in position. The top of the cylinder 10, is then swung back as
shown by dotted lines in Figure 16 and the header withdrawn with its end piece
fixed in position. It is next taken and dropped into the welding fire C, with its

page_text: draw-box 15, attached, and heated to a welding heat for subsequent operation in
the welding machine.
The end welding machine consists in a series of welding rolls and means for
contracting the same about the end of the header, and also a shearing plate on
which the inserted end piece of the header is superposed; the said plate adapted
for passage between the welding rolls in such manner as to sever the surplus metal
on the end of the tube beyond the end piece, and of other auxiliary features for
moving the header, as hereinafter described.
H, Figures 20 and 21 represents a suitable frame of the welding machine com-
posed of four vertical standards which support the removable cross-bars I.
E, is the crane, operated by hydraulic cylinder 2, and suspending the header F,
upon the trolly 3, adapted to transfer the same, in its vertical position, to and from
the welding machine. 15, is the draw-box for supporting the header and resting the
same in position upon the cross-bars of the frame H. J, represents a suitable
frame, bearing hydraulic cylinders 4, the rams 5, of which are adapted to hold
down the flanges of the draw-box 15 and retain the latter with the header in place
preparatory to welding. 7, is a stationary frame connected by bolts 8, to the base
of the frame H, and upon the stationary frame 7, are supported the several
welding rolls 9 upon the respective sides of the box or header to be welded. The
welding rolls 9, are connected to the head 7, by means of links 6, in which the said
rolls are pivoted and obtain their lateral movement. 20, is a vertically movable
frame guided by the rods 8, and by other suitable guides, which carries the cams 21,
that engage with the outer surfaces of the links 6, and so located as to contract the
welding rolls 9, during the early part of the upward movement of said frame 20,
and to subsequently retain the said rolls in their contracted position when the
header F is forced upward through said rolls. The upper head of the frame 20 is
adapted to engage with and lift the cross bars I, at the period of stroke when the
rolls 9 have been contracted, and thus draw the header F, upward by means of the
draw-box 15, as shown in Figure 27.
22 is a supporting block which rests on the stationary head 7, previous to
operation, and during operation rises independently of, but simultaneously with the
frame 20, acting as a follower which is designed to maintain the end piece 30, in
its proper relative position during compression. The block 22 is provided at its
upper extremity with a removable core 23, which is designed for header ends
having a tube hole wherein such core is adapted to enter and maintain the form of
the hole which has been previously punched. In the welding of solid ends, the
core 23, is removed from the block 22. 25, Figures 22, 23, 25 and 33, is the
shearing plate, the edges of which extend to a size which will pass the rolls 9, and
which serve to shear off the surplus metal of the end of the header when it is
welded. This plate may be constructed as shown in Figures 23 to 27 inclusive,
thus adapted to shear the edges flush with the end piece, or such shear may be,
and preferably is, constructed as shown in Figures 20, and 21, and in Figures 31
to 36 inclusive, wherein the top bevel provided thereto is adapted to obtain an
entrance into the contracted end of the header when it is brought to the welding
machine in the contracted form shown in Figure 31. The top bevel 26, of the
shear 25, after passage through the rolls, leaves the header end in the form of a
sunken panel when finished as shown in Figure 33.
The frame 20, is elevated by the ram 36, of the hydraulic cylinder 35, and the
block 22, subsequently raised when the ram 36 engages with the shauk 37 thereof;
the frame 20 and block 22, thenceforth moving together.
The draw-box 15, may be variously modified. In Figure 37 I show a sectional
view of the draw-box applied to Figures 20 and 21 which is composed of two parts
having curved faces adapted to fit the serpentine contour of the header F; one
part being keyed to the Hanks of the other by a suitable key 40. In Figures 23
to 27, inclusive, I indicate a modification of the draw-box 15, wherein it consists of
two side plates 41, 41, that are clamped to the flat faces of the header F, and

page_text: rigidly connected thereto by means of the caps 42, Figure 24, bolted together, into
the tube holes of the header.
The operation of the invention is as follows:-
The header is taken from the welding fire while suspended on the crane E; the
draw-box 15 being attached; and the header with the end to be welded previously
placed is dropped into the welding machine with its heated end between the rolls 9,
as shown in Figure 20. Pressure is then applied to the two small cylinders, 4, 4
and the rams descend and force the draw-box 15 onto the cross-bars 1, 1 of the
frame, as shown in Figures 20 and 21. Pressure is next applied to the cylinder 35,
and the ram 36, raises the frame 20, surrounding the rolls, and with it the four
inclined surfaces or cams 21, which act on the links 6, of the welding rolls, force
the latter inward against the four sides of the header above the end which is
inserted, Figures 21 and 23. A further movement of the machine engages with
the top bars I, I, the same being elevated by the frame 20, which, owing to the
predominating pressure applied to the plunger 36, backs up the small rams 5, 5,
that have previously retained the draw-box 15 in position. At this period, the
block 22, and shearing plate 25 are engaged to rise with the other parts simul-
taneously while the header is drawn upward through the closed welding rolls 9,
thus squeezing down the four sides of the header hard on to the end pieces, and
welding the same all around as shown successively in Figures 23, 25 and 26, the
shearing operation taking place simultaneously with said upward movement of the
header, Figure 27, showing the position of the parts at the completion of the
operation, which are subsequently retracted to the first position shown in Figure 20.
Having now particularly described and ascertained the nature of the said inven-
tion and in what manner the same is to be performed as communicated to me, I
declare that what I claim is :-
1. In a press for shaping and perforating plates, the combination of two male
dies, one for shaping the plate, the other for perforating it, and suitable female dies
in alignment therewith, together with means for adjusting the one of said male
dies with reference to the other in different fixed positions; the one wherein the
perforating die projects in advance of the shaping die; the other wherein the
shaping die is brought flush or in advance of the said perforating die for
the
purposes set forth.
2. A press fitted with compound dies substantially as described, in combination
with telescoping cylinders attached to the respective heads of the press independent
of the dies for holding and guiding said dies, substantially as described.
3. A. press fitted with compound dies substantially as described, combined with
telescoping cylinders attached to the respective heads of the press for holding and
guiding the dies, and provided with a lateral channel therethrough extending
between the dies for the reception of the plate, substantially as described.
4. In an end placing machine for headers or other tubes, a vertically movable
inserting block for supporting the end piece, means for forcing the header down
over the inserting block, and lateral to the inserting block a series of movably
supported rams provided with means for moving them radially inward to advance
upon the sides of the header after the end piece is inserted, and clinch the same,
substantially as described.
5. In an end placing machine for headers or other tubes, an inserting block, a
limiting stop attached to the header, an abutment for limiting the descent of the
same, and a hydraulic ram for advancing the header against the said block.
6. In an end placing machine for headers or other tubes, an inserting block for
the end piece, a stop forming a rest attached to the header adapted to support the
same vertically upon the machine, and above the header a hydraulic cylinder for
advancing the same and a suitable swivelling frame for throwing the cylinder into
or out of alignment with the header when active or inactive respectively for the
purpose described.
7. In an end placing machine for headers or other tubes, a series of movably

page_text: supported rams provided with means for moving them radially inward and
compressing the sides of the header, a vertically movable inserting block for the
end piece, a rod extending through and movable within the frame work of the
machine for moving the said block, and means for forcing the header over
the block opposite the rams, substantially as and for the purpose described.
8. In an end welding machine for headers or other tubes, a series of exterior
welding rolls with means for moving them inward, a movable frame adapted for
connection to the header for drawing it longitudinally between the said rolls, and
means for supporting the end piece during its passage between the rolls, as set
forth.
9. In an end welding machine for headers or other tubes, a series of exterior
welding rolls with means for moving them inward, a movable frame adapted to
connect with and move the header longitudinally between the said rolls, and a
follower for supporting the end piece during its passage between the rolls.
10. In an end welding machine for headers or other tubes, a series of welding
rolls, a movable frame adapted to connect with and move the header longitudinally
through the said rolls, a follower, and therein a shearing plate substantially as
described, adapted to support the end piece and move with the header between the
rolls and shear the surplus metal of the tube simultaneously with the welding.
11. In an end welding machine for headers or other tubes, a series of movably
supported welding rolls, a movable frame adapted to connect with and move the
header longitudinally through the rolls, and upon said frame, the cams or inclined
surfaces such as described, adapted to move the welding rolls inward and
subsequently retain them in their inward position during the upward motion of said
frame.
12. In an end welding machine for headers or other tubes, a series of movably
supported welding rolls adapted to surround the end of the header, a drawing
frame for moving the rolls inward and drawing the header longitudinally through
the same, and a draw-box constructed to be attached to the header and to support
it upon the said drawing frame substantially as described.
13. The combination in a machine for end welding headers or other tubes of a
movably supported welding rolls, the drawing frame having cams with inclined
surfaces adapted to move the welding rolls inward, and means for moving the
header longitudinally through the rolls, a hydraulic ram for operating the drawing
frame, and a follower for advancing the end piece adapted for engagement with the
said ram subsequent to the inward movement of the said rolls, and simultaneously
with the advancement of the header between the same, substantially as described.
14. In a machine for end welding headers or other tubes, the combination of a
series of exterior welding rolls, a drawing frame and means for moving the same to
move the rolls inward, and to draw the header longitudinally between the rolls, a
draw-box constructed to be attached to the header, a stationary support adapted to
hold the draw-box in the path of movement of the drawing frame, fluid pressure
cylinders and rams therein for holding the draw-box upon the stationary support,
and adapted after the welding rolls have been moved inward, to yield to the
motion of the drawing frame when the latter abuts on the draw-box, substantially
as and for the purpose specified.
Dated this 1st day of September 1893.
CRUIKSHANK & FAIRWEATHER,
62, St. Vincent Street, Glasgow, Agents.