Tool for adjustably aligning pipe flanges and structural members

Tool for selectively angularly aligning an apertured flange so that the flange can be fixed to a pipe at a selected angularity relative to bends in the pipe. Improved device for attaching the level to the flange are shown, and the level can further be provided with means enabling it readily to be used also to set the grade of a pipe or of a structural member.

In the fitting up and laying of large-diameter pipe, where apertured pipe flanges are welded to respective lengths of pipe, and then adjacent pipe flanges are bolted together, the correct angular alignment of the pipe flanges is essential or theycannot be joined by bolts. This represents no particular problem when two straight unbent lengths of pipe are to be joined, because the entire length of one pipe can be rotated so the apertures in the pipe flanges line up, and then the flange at theother end can be welded on, and the process repeated. It is not so simple, however, when one of the pipes has a joint in it that forms an angle, or when both of them do.

It is extremely inconvenient to weld a pipe flange onto a pipe with the pipe already installed in its ultimate installed position. It is better practice to lay the jointed pipe flat on the floor, and do the job in a shop. Or, if the job is donein the field, it is better practice to perform the task at ground level. However, there is a more complicated angular relationship, when the pipe is bent than when it is straight, because when the jointed pipe is erected, the pipe flange will haverotated. Accordingly, when a pipe flange is attached to a length of bent pipe, allowance must be made for the change in spatial alignment which will result when the pipe is erected in its ultimate position.

An object of this invention is to provide a tool for angularly aligning a pipe flange relative to a pipe which is easy to use, and accurate in its results.

The task of aligning pipe flanges is not a new one, and tools have been designed to accomplish this function. An example is the "Dial-Angle-Flange-Level" distributed by Contour Sales Corporation, 6515 East Compton Blvd., Paramount, Calif. 90723, shown in its publication Form S-300. This device has a bar which is attachable to a pipe flange at two apertures thereon, and an angularly adjustable protractor dial bubble level. Two cylindrical pins are attached to the bar and projecttherefrom. Their spacing apart is adjustable. In use, the pins are inserted into holes in the flanges. The accuracy of the alignment depends in part on how closely these pins fit in the flange holes, or if they are loose in the flange holes, howsimilar is their position in the holes. In the same publication there is shown a "Pro-Mag Level" which has magnets to hold a body in axial alignment with a pipe, and an angularly adjustable bubble level.

The tool according to this invention comprises a body, a protractor dial bubble level adjustably rotatably attached to said body, and a pair of attachment means aligned with one another along a datum line related to the bubble level. Eachattachment means includes a pair of self-centering members, one of which is movable toward the other, so as to clamp the body to the flange. The self-centering members are proportioned to enter the apertures so as to center themselves and thereby alignthe body with the apertures. A movable one of the members is threadedly attached to a bolt which is coaxial with both of the members.

According to a preferred but optional feature of the invention, edges of the body are parallel to a datum line drawn through the centers of the self-centering members so those edges are related to the bubble level when the device is used to setthe grade of a pipe or structural member.

The bubble level is mounted to the body via a protractor dial, the bubble level being fixed to the dial, and the dial being rotatable, and provided with means to restrain it ina selected angular position.

At least one of the attachment means is attached to the body in a slot aligned with the datum line so the body can be attached at apertures which have various spacingsapart, one of the self centering members being threaded onto the bolt so as to hold the attachment means at a selected position.

The body can be provided with magnet means to hold it in axial alignment on a pipe or structural member or the like, to enable the grade to be set, and thereby to increase the number ofuseful functions the tool can perform.

It will further be noted that this tool is applicable to a wide range of aperture separations simply by loosening one or both of the attachment means relative to the body, and sliding the bolts along the slots to the correct position and thentightening them. The first self-centering members make a tight clamping fit to establish the separation of the attachment members, and the other self-centering members are tightened down to hold the tool to the flange. The device thereby constitutes areadily manufacturable, convenient to use, device which facilitates its intended functions.

Segmented flange coupler for grooved pipe

Segmented flange coupler is disclosed for connecting the free end of a grooved pipe to a fitting having a flange connector. The segmented flange coupler is formed of end-to-end connected individual coupling segments which are configured to move both circumferentially and radially into concentricity during the tightening of their connecting bolts.

This is achieved by providing complementary surfaces of revolution about their overlapped bolt receiving apertures. These surfaces of revolution are preferably in the form of mating convex and concave conical surfaces.

This application relates to a segmented flange coupler, whereby a pipe having a groove formed in its external circumference adjacent a free end of the pipe, can be connected directly to a fitting having a flanged connection.

It is presently known to form such a segmented flange coupler from a plurality of coupling segments, generally arcuate in shape, which are bolt connected in an end-to-end relationship about the circumference of the pipe. Typically two such coupling segments, of a generally semi-circular shape, are employed. However for large pipe sizes three or more coupling segments may be utilized.

The ends of the coupling segments include bolt receiving apertures for connecting the successive coupling segments together. The coupling segments typically include a key which extends within a circumferential groove of the pipe. Oftentimes the pipe may be somewhat out of round such that the bolt receiving holes of the successive coupling segments will not line up. Accordingly, appreciable force must then be applied to appropriately bring the coupling segments together, as near as possible, to appropriately engage the pipe circumference.

Typically, such prior constructions, for example, the Style 741 segmented pipe coupling available from the Victaulic Company of America, has included radially extending ears at the ends of the coupling segments being bolt connected. The ears must then be engaged with a tool, such as a pliers or channel lock, to bring the ears together such that the bolt can pass through the overlapped apertures for the tight connection of the adjacent coupling segments. Further, it has been experienced that the bolt receiving apertures in such coupling segments must be located with a high degree of accuracy.

Other constructions are also known to bring the adjacent coupling segments into circumferential alignment.

Thiessen, U.S. Pat. No. 3,895,833, provides a flange adapter for use in such a situation. Thiessen's flange adapter includes two or more coupling segments that are connected to each other in end-to-end relationship by means of bolts that are employed to secure the respective coupling segments directly to the flange of the fitting.

Thiessen employs ramp cams on the respective ends of his coupling segments that are interengaged when the coupling segments are assembled onto the grooved pipe. The ramp cams cause circumferential movement of the assembled segmented pipe coupling at the time the bolts are tightened down. This causes the respective flange segments to bottom down on the bottom wall of the groove formed in the pipe, and provide a circumferential alignment between the pipe and the fitting.

However, the provision of such ramp cams carries with it a disadvantage that the flange segments must either be assembled relative to each other prior to the insertion of the traction bolts, with the ramp cams on the respective flange segments interengaged or, the keys of the respective segments must be of lesser width than the width of the pipe groove. If, however, the keys do not engage the side walls of the pipe groove, then, a flexible coupling results, as opposed to a rigid intercoupling of the pipe and the associated fitting.

There is no provision for radial alignment, and hence no guarantee that the flange segments will be truly concentric as related to the longitudinal axis of the assembled coupling, and in turn, as related to the longitudinal axis of the pipe.

Free play of the bolts in the bolting pads of the respective flange segments, will permit the ends of the respective flange segments to be displaced in the radial direction relative to the juxtaposed flange by a distance that is equal to the difference between the diameter of the bolt holes in the respective flange segments and the diameter of the bolts employed for securing the respective segments to each other.

Further, Thiessen's ramp cams, which extend radially of the axis of the coupling, are inoperative to produce any force that acts to move the respective flange segments into concentric relationship relative to the central axis of the coupling.

This can cause problems at the time the flange segments are tightened onto the fitting by means of the bolts if the flange segments at that time are out of concentric alignment. As a consequence they do not bottom down correctly on the bottom wall of the pipe groove, until such time as they are forced into concentric relation by their engagement with the bottom wall of the pipe groove. However, at the time the bolts are being tightened down, to cause the diameter of the flange coupling to decrease, there then exists a considerable frictional restraint against any radial movement of the flange segments relative to each other, with the consequence that the flange segments are not truly concentric with each other. Hence there is no guarantee that the flange segments have in fact bottomed down correctly into full face engagement with the bottom wall of the pipe groove.

If the segments have in fact not bottomed down fully on the bottom wall of the pipe groove, then, the strength of the interconnection is materially affected, as is the probability that a rigid connection has not been effected between the pipe and the fitting by the flange segments. In such a situation, the pressure that the coupling can withstand will be reduced.

It is an object of this invention to provide a segmented flange coupling that, prior to and during tightening down of the traction bolts will move both circumferentially and radially into truly concentric relationship with each other, and also into truly concentric relationship with the bottom wall of the pipe groove. This movement advantageously provides a segmented flange coupler that is entirely predictable in its securement of the pipe to the fitting, such that true rigidity of the pipe relative to the fitting is accomplished in an entirely automatic self-adjusting manner.

The present invention employs interfitting surfaces of revolution, preferably cones, on the ends of the respective flange segments about the bolt receiving apertures. These interfitting surfaces, which may initially interengage with each other in a random position of concentricity of the flange segments, then act to draw the flange segments into true concentricity as the bolts are tightened down.

Top flange hanger with strengthening embossment

Structural connector for connecting first and second structural members has a substantially planar first flange and an embossment in the first flange, and the embossment in the first flange is formed with first and second sections.

The first section generally extending uniformly to a first level above the top surface of the substantially planar first flange, that is different from a level to which the second section generally uniformly extends, the first and second sections being joined to each other at a distinct transition portion where the embossment sharply descends from the level of the first section to the level of the second section. The structural connector can be made with a bend that forms a first member adjacent the first flange and the embossment can extend through the bend into the first member.

The structural connector of the present invention has particular application in the field of structural hangers where an elongated, generally horizontally disposed structural member is hung from a supporting structure, both being part of thestructural frame of a building.

In light frame construction, it is common to hang the joists supporting the floors of the building from horizontally disposed members often called headers, beams or ledgers. The joists can be supported by hangers which are attached to theheaders, beams or ledgers. One type of hanger used is called a top flange hanger. A top flange hanger has a portion or member that rests on the top surface of the supporting structure, increasing the strength of the connection.

Unfortunately, the presence of the top flange can interfere with the setting of the sub-flooring members on top of the joists and the headers and ledgers. The top flanges create an unevenness in the surface upon which the sub-flooring isinstalled.

Preferably, the flat top surfaces of the joists, headers and ledgers will all be uniformly level and set at the same elevation, once the members are set in place, although deviations are often made to allow for shrinkage of members made from woodor having wood sub-components. Also, preferably, the sub-flooring used is made up of large sheets of relatively thin planar material, such as plywood or oriented strand board, that can be laid down on the level top surfaces of the headers and ledgersresulting in a uniformly flat surface for laying down the flooring.

Thus, it is desirable to minimize the thickness of any members, such as fasteners, fastener heads or hanger components that will project above the level of the top surfaces of the ledges, headers and joists. When such members project above theultimate top level of the structural members of the flooring, they create unevenness in the surface for the subflooring, commonly known as reveal problems.

Thus, when top flange hangers are used, it is desirable to make the material of the top flange as thin as possible. However, the top flange must still be strong enough to carry the desired loads imposed on the hanger. One means of strengtheningthe top flanges of hangers is to create embossments or deformations in the top flange hanger that extend into the back members of the hangers. The problem with typical strengthening deformations or embossments is that too much of the material of the topflange is deformed to too great a height, thus creating reveal problems.

It is a specific object of the present invention to provide a structural hanger for supporting a structural member from a supporting member, where the structural hanger is made with a top flange that rests on the top surface of the supportingmember, and the top flange of the hanger is formed with strengthening deformations that increase the strength of the structural hanger while minimizing the profile of the top flange of the hanger.

It is a further object of the present invention to provide that the level of the first section of the embossment of the structural connector is higher above the top surface of the first flange than the level of the second section of theembossment, and the higher first level is closer to the bend between the first flange and the first member than the second section. The inventors have found embossments which are taller near the edge of the first structural member or supportingstructural member and then decrease in height but continue to extend a substantial distance along the top flange, can provide sufficient strength to structural hangers made from light gauge steel, while providing minimal interference with the laying ofthe subflooring.

Provide a top flange hanger made from galvanized sheet steel or stainless steel that does not need to be welded, and, therefore, does not need to be painted to protect the hanger from corrosion.The top flange hanger with low-profile strengthening deformations in its top flange or flanges that can be formed from sheet steel material on a fully automated die press with no secondary orfinal bend operations being necessary.

Flanged connector for HVAC ducting

Flange rings for the connection end-to-end of thin, double walled circular ducting includes a first generally-circularly shaped ring having an outer insertion flange for connection to the outer wall of the double-walled duct.

The first ring also includes: an exterior mating flange extending transversely from the outer insertion flange to define a first mating face; and an exterior hem that is substantially concentric to the outer flange to extend outwardly from the outer perimeter of the exterior mating flange. The flanged ring also includes: a second ring having an inner insertion flange connectable to the inner wall of the double-walled duct; the interior mating flange transverse from the interior insertion flange to define a second mating face; and an interior connection hem substantially concentric to the inner insertion flange and extending from the outer perimeter of the interior mating flange to overlap and be connected to the outer insertion flange.

Joint assemblies are well known for the connection of the ends of adjacent rectangular, circular, and oval HVAC duct sections. U.S. Pat. No. 5,129,690, to Meinig, recites prior art relating to such assemblies and discloses an apparatus forconnecting the ends of oval duct sections without disclosure of the method of making the apparatus; the patent does refer to U.S. Pat. No. 4,516,797, to Meinig, which discloses a one-piece flanged ring for connecting the ends of circular duct sections. U.S. Pat. No. 4,516,797 discloses a method for producing the flanged ring by contouring and then bending an elongated sheet-metal strip into an annular shape resulting in a flanged ring having an axial slit and claiming a method for producing a flangedring characterized as an elongated sheet metal strip which is contoured and subsequently bent into annular form.

The machine method used to produce such a flanged ring is known to include roll forming. However, roll forming is limited generally to sheet-metal less than 10 gauge with roll forming causing tearing or breaking of sheet-metal in the productionof flanged rings from thinner sheet-metal of gauge 10 or greater. Circular flanged rings, produced by roll forming, and thin-walled sheet-metal ducting generally do not have an absolutely circular cross section. The predominant means of manufacturingHVAC ducting is in the form of spiral seam tubes made up of helical wound sheet-metal strips with the strips interconnected by means of lock seams. The lock seams stand out from the outer duct face.

Objects of this invention are double wall circular and oval flanged rings from Lock Form Quality steel of gauge 10 to 20, for the connection of the ends of thin-, double-walled circular and oval sheet-metal tubes or ducting and how to make themby spinning, forming, and trimming, with standard machine tools and machining processes. The present invention is capable of making Flanged Rings that comply to the T24 flange profile and other profiles of the Sheet Metal and Air-ConditioningContractors National Association (SMACNA). The method includes LFQ steel strips that may be rolled into flanged ring band stock strips having strip first and second ends which are butt welded together with a tungsten inert gas process with no filler. Aspinning die, which is balanced and which has structural means or supporting structural member means, receives the flanged ring band stock which may be secured within the spinning die by appropriate means, for example by clamp means. The spinning die isrotated by means, for example by a lathe, and machine tools are employed to stretch, form and trim the flanged ring band stock to produce a first circular flanged ring. A second circular flanged ring may be produced by the same method in a secondspinning die and then attached to the first circular flanged ring to form one double-wall circular or oval flanged ring for the connection of circular and oval thin gauged double-wall pipe or ducting sections.

One preferred embodiment of the flanged ring profile described herein constitutes the Sheet Metal and Air-Conditioning Contractors National Association (SMACNA) standard T24 Flange Profile. The profile disclosed is not limited to the SMACNA T24profile. However, the method disclosed produces circular or oval flanged rings while the SMACNA T24 Flange Profile refers solely to flanges for the connection of rectangular ducting sections. This disclosure is the only known method of producing theSMACNA T24 Flange Profile for circular and oval flanged rings from 10 or greater gauge LFQ steel. The SMACNA T24 Flange Profile or cross section produced by the method described has an outer insertion flange portion which is secured within the spinningdie by means including clamp means, an exterior mating flange portion which is stretched and formed and which meets and matches an opposing mating flange portion, an exterior hem portion which is formed, and a return flange, and an inner insertion flangeportion which is secured within the second spinning die by means including clamp means, an interior mating flange portion which is stretched and formed and which meets and matches an opposing mating flange portion, and an interior hem portion which isformed.

The oval double-wall flanged ring is produced by cutting a circular, double-wall flanged ring along a diameter to produce approximately equal sized semi-circular flange ring portions. Equal length SMACNA T24 Linear Segments of the SMACNA T24Flange Profile are produced, for instance by roll forming, and are welded to the semi-circular flanged ring portions to produce the oval flanged ring.

One preferred embodiment of the present disclosed method results in the production of the SMACNA T24 Flange Profile from 10 to 20 gauge Lock Form Quality steel (under 30,000 psi yield/tensile, galvanized G60; however, any metal which can beturned in the following described process and which can be welded may be used for production). The preferred embodiment of the described method requires the preparation of flanged ring band stock from 3.87511 wide 10 to 20 gauge LFQ steel. The materialand material width may be varied as preferred.

Exhaust system having low-stress exhaust manifold flange

Exhaust system in an internal combustion engine has an exhaust manifold, an exhaust flange is connected to the exhaust manifold, and a turbocharger is connected to the exhaust flange. The turbocharger has an exhaust inlet flange connected to the exhaust flange. The exhaust manifold has a first passage and a second passage, and the exhaust flange has a first exhaust port and a second exhaust port. The exhaust ports of the exhaust flange each have a generally triangular cross-sectional configuration.

The use of turbochargers in internal combustion engines is well known. Turbochargers increase the mass of air supplied to the engine thereby enabling the increase of the power output of the engine. In addition, the efficiency of the engine is increased by the turbocharger's utilization of the thermal energy contained in the engine's exhaust gases.

However, the connection between a turbocharger and the engine has posed various design challenges. For the engine to operate at optimum efficiency, the engine must transfer as much energy as possible from the exhaust gases of the engine to a turbine of the turbocharger, thereby maximizing the boost provided by the turbocharger. Energy is lost from the flow of exhaust gases in the exhaust manifold due to wall friction, area changes in the manifold, and directional changes in the manifold due to flow separation and the creation of secondary flows. All three of these causes of energy loss are typically present in the area of the exhaust manifold where it joins the turbocharger, i.e. the exhaust manifold flange. Therefore, an optimal exhaust manifold and exhaust manifold flange design is successful in minimizing these energy losses.

When energy is lost from the exhaust gas flow through the exhaust manifold flange and in the area of the exhaust manifold near the flange, the energy is typically transformed via convection into thermal energy in the exhaust manifold and flange. Therefore, if the design of the exhaust system reduces the amount of heat absorption from the exhaust gas flow by the exhaust manifold and the exhaust manifold flange, the energy transferred to the turbine of the turbocharger is increased and the efficiency of the engine is improved. In addition, the exhaust manifold and exhaust manifold flange design that reduces the heat absorption of the manifold and flange increases the operating life of the manifold flange and turbocharger. When the exhaust manifold flange absorbs an excess amount of thermal energy, the flange typically develops stress cracks. Such cracking results in failures and not only requires replacement of the flange and/or a portion of the exhaust manifold with which the flange is integral, but it can also cause damage to the turbine of the turbocharger. For example, debris from the cracked and failed manifold passes into the turbine of the turbocharger. This problem of cracking exhaust manifold flanges has been exacerbated by the recent dramatic increases in internal combustion engine exhaust gas temperatures caused by the industry's drive to increase the power output of engines while reducing unwanted emissions.

An exhaust manifold flange must also have the structural integrity to support a rigid connection with a turbocharger. This rigid connection reduces vibrations between the turbocharger and the flange and ensures that a good seal is maintained between the turbocharger and flange. In addition, the connection between the exhaust manifold flange and the turbocharger is typically the only rigid connection between the turbocharger and the engine. All other connections between the turbocharger and the engine are flexible so that no significant forces will be applied to the turbocharger from thermal expansion of the turbocharger, the engine or the connections. Therefore, an exhaust manifold flange must be capable of supporting the weight of the turbocharger and other forces introduced by the turbocharger to the engine.

One attempt at designing an exhaust manifold flange to reduce the incidence of cracking of the flange is illustrated in U.S. Pat. No. 5,406,795 ("the '795 patent") issued to Raub et al. on Apr. 18, 1995. The flange disclosed in the '795 patent has two exhaust ports. The two exhaust ports are generally trapezoidal in shape and are separated by a thin straight center wall. Experimentation has shown the flange is not capable of handling the increased temperature of the exhaust gases produced by today's internal combustion engines. The thermal energy destroys the center wall. Therefore, an exhaust system is needed that combines the exhaust manifold, the exhaust manifold flange and the turbocharger permitting a rigid connection between the flange and the turbocharger and reducing the thermal energy absorbed by the manifold and the flange. Thus, the operating life of both the flange and the turbocharger is increased, the efficiency of the engine is improved, and the power output of the engine is increased.

An exhaust system has an exhaust manifold, an exhaust flange connected to the exhaust manifold, and a turbocharger. The exhaust manifold has a plurality of passages, and the exhaust flange has two exhaust ports in fluid communication with the exhaust manifold passages. The exhaust ports of the exhaust flange have a generally triangular cross-sectional configuration. The turbocharger has an exhaust inlet flange that is connected to the exhaust flange. The exhaust inlet flange has two inlet ports that are in fluid communication with the exhaust ports of the exhaust flange.

In another aspect of the exhaust system, the exhaust flange has a first axis that intersects each of the exhaust ports. The exhaust flange also has a first outer surface, a second outer surface, a third outer surface, and a fourth outer surface. At least one of the third outer surface and the fourth outer surface is substantially parallel with the first axis.

A method of manufacturing an exhaust manifold for use in a high-temperature engine includes forming a first exhaust port and a second exhaust port, each exhaust port having a generally triangular configuration. Each exhaust port is then surrounded by a wall thickness.

A high-temperature engine has a cylinder block, a cylinder head, an exhaust manifold connected to at least one of the cylinder block and the cylinder head, and an exhaust flange connected to the exhaust manifold. The exhaust flange has a first exhaust port and a second exhaust port, each exhaust port having a generally triangular configuration.

Corrugated-core flanges for spools and reels

A flange design providing improved strength, fracture resistance, and the like using corrugations extending substantially radially from an arbor aperture toward a rim portion. A spool or reel may include a tubular member to receive a stranded material wrapped therearound. A first flange comprising a core portion and an outer portion may secure to one end of the first flange engaging the tubular member.

A second flange may secure to the other end of the tubular member. The core portion of a flange may comprise an arbor wall defining the perimeter of an arbor aperture. The arbor wall may be directly contacted and supported by a plurality of corrugations extending radially therefrom. The outer portion of a flange may contact the core portion and extending radially away therefrom to an outer edge to restrain the stranded material in an axial direction.

The first flange further comprising corrugations substantially rectangular in radial cross section and extending radially from proximate the core radius to proximate the outer radius, the corrugations comprising a plurality of webs, each web of the plurality of webs being offset axially from and dimensionally of the same order of magnitude am adjacent webs of the plurality of webs, and a plurality of connecting walls, each connecting wall of the plurality of connecting walls extending between two adjacent webs of the plurality of webs, the connecting walls and webs being molded of a homogeneous material.

Spools and reels have suffered from a lack of intelligent application of technology for many years. Spools date back hundreds if not thousands of years. Wooden spools and reels have been used in the textile industry as well as various electrical industries for many years with almost no innovation in their structures. Some use of plastic materials began a few decades ago. Nevertheless, manufacturing techniques continue to fall short of implementing all of the principles of engineering that are available.

Manufacturing techniques tend to focus on the simplicity of manufacture, and the simplicity of design, rather than the optimization of strength, weight, stiffness, non-catastrophic failure modes, and the like. Some of these latter considerations have been found to be significant in the manufacture and use of plastic spools and reels. Accordingly, developments by Applicant have provided improved methods for providing spools and reels having substantially reduced weight with improved stiffness and cost. Moreover, failure modes are available to provide "graceful degradation" of performance rather than catastrophic failure of spools and reels in situations such as the dropping of loaded reels or spools.

Spools and reels are used in many industries. However, in the wire and cable industry, the comparative weight of stranded material on a reel or spoon is greater than others of similar size in other industries. Fracture of flanges near an outer diameter thereof is common if dropped. Likewise, due to the conventional shapes of central tubes (hubs, cores, etc.), the junctions with flanges are not inherently resistant to fracture from impact loads caused by dropping. Dropping from a working bench is common for reels and spools. Manufacturing processes for manufacturing reels and spools, as well as manufacturing processes for wire and other stranded materials, typically compels smooth circumferential edges at the outermost diameter of a flange. Accordingly, a spool not retained on an arbor during use (using the wire, rather than manufacturing and taking up the wire) may roll easily across any flat surface. Thus, while a spool or reel is considered tare weight in shipping wire and cable, and a disposable item whose cost is to be minimized a spool or reel must function reliably and durably during its entire useful life.

Otherwise, a substantial length of stranded material may be damaged beyond use. The material held on a spool or reel having a value of a few dollars may itself have a value of one thousand times the cost of a spool. A value two orders of magnitude greater than that of the spool is routine for wire of common usage.

In the art, a typical spool has a tube portion extending between two flange portions positioned at either end of the tube portion. A spool may have a rounded rim or rolled edge at the outermost diameter. This rim serves structural as well as aesthetic and safety purposes. Spools may be manufactured in a variety of tube lengths. Each flange is fitted by some fixturing to one end of the tube and there retained. Details of spools are contained in the U.S. Pat. No. 5,464,171 directed to a mating spool assembly for relieving stress concentrations, incorporated herein by reference.

The impact load of a spool of wire dropping from a bench or other work surface to a floor in a manufacturing environment is sufficient to fracture the spool in any of several places. Fracture may damage wire, preclude removal, or release the wire in a tangled, useless mass.

Spools may break at the corner where the tube portion meets the flange portion or may fracture at an engagement portion along the tube portion. Spools may break near the corner between the flange and the tube portion where a joint bonds or otherwise connects the tube portion to the flange portion.

In drop tests, a spool may be dropped axially, radially or canted off-axis. In a radial drop, spools that break typically fail near the middle of the length of the tube. In axial drops, flanges may separate from tubes in failed spools. In an off-axis drop, flanges typically fracture, and may separate from tubes, releasing wire.

Large spools are typically called reels in the wire industry. Heavy-duty reels of 12 inches in diameter and greater (6 feet and 8 feet are common) are often made of wood or metal. Plastic spools of 12-inch diameter and greater are rare and tend to be very complex. The rationale is simple. Inexpensive plastics are not sufficiently strong or tough to tolerate even ordinary use with such a large mass of wire or cable wrapped around the spool.

Moreover, large flanges for reels are very difficult to manufacture. Likewise, the additional manufacturing cost of large spools is problematic. High speed molding requires quick removal after a short cycle time. Flanges are typically manufactured to have very thick walls. Increased thicknesses directly lengthen cycle times. Thus, designs do not scale up. Therefore, the flanges have very slow cooling times and molding machines have low productivity in producing them.

The reels have an additional difficulty when they are dropped during use. The flange do not stay secured. The flange and tube are often precarious wooden assemblies held together by three or more axial bolts compressing the flanges together. The tube is prone to slip with respect to the flanges, breaking, tilting or otherwise losing its integrity under excessive loads. Such loads result from the impact of dropping onto a floor from a bench height or less. For the largest reels, rolling over or into obstacles or from decks during handling is more likely to be the cause of damage.

Hinged annular shaft flange

An annular shaft flange that can be positioned along the length of a shaft and secured to the shaft to prevent movement of an article along the length of the shaft. The annular shaft flange includes a pair of nesting ends that are attachable to each other using a mechanical interlocking member.

Previous devices, such as snap rings, cotter pins or flip pins require the shaft to be machined or drilled, thereby weakening the shaft and adding additional cost to the manufacturing process. A locking ring requires no machining, but has a greater cost penalty and can only be placed on the shaft if the diameter of the shaft is constant or has an area of reduced diameter.

Presently, annular shaft flanges, such as shown in Nell U.S. Pat. No. 5,857,800, owned by the assignee of the present application, have been successful in providing a method of securing an object along a shaft and preventing the object from moving along the length of the shaft. However, the shaft flange taught by the Nell '800 patent preferably uses a spot weld to secure the two ends of the shaft flange in place. Although spot welding has proven to be an effective method of retaining the two ends of the shaft flange, a need has arisen to provide alternate methods of securing the two ends of the shaft flange to eliminate the need for a spot weld. The apparatus and method of the present invention address this need in a novel manner.

In a first embodiment of the invention, the annular shaft flange includes a flange body that is movable between an open position and a closed position. A hinge is formed in the flange body to permit movement of the flange body between the open and closed positions.

The flange body includes an inner curved engagement surface that is sized to interact with the outer surface of the shaft when the shaft flange is moved to the closed position. The curved inner engagement surface provides an area of frictional engagement between the shaft flange and the annular shaft.

The body of the annular shaft flange extends between a first end and a second end. The first and second ends are spaced from each other when the shaft flange is in the open position. The first end of the flange body includes a first attachment projection, while the second end of the flange body includes a second attachment projection. When the shaft flange is moved to the closed position, the first attachment projection is positioned in contact with the second attachment projection.

The first and second attachment projections of the shaft flange extend generally parallel to the longitudinal axis of the shaft to which the shaft flange is being attached. Each attachment projection projects radially away from the shaft to provide areas for joining the first and second ends of the flange body to each other. Preferably, an attachment member, such as a rivet, passes through the first and second attachment projections such that the attachment member can secure the flange body in the closed position.

In the preferred embodiment of the invention, the annular shaft flange includes a shaft engagement lip that extends axially from the first end face of the flange body. The shaft engagement lip increases the overall axial width of the shaft flange and combines with the flange body to define the curved engagement surface. The shaft engagement lip increases the surface area contact between the annular shaft flange and the shaft to further prevent movement of the shaft flange along the shaft.

In an alternate embodiment of the invention, the annular shaft flange includes a flange body having a flange portion having a width defined by a first end face and a second end face. The first and second end faces are spaced from each other along the longitudinal axis of the shaft to which the annular shaft flange is mounted. The flange body includes a hinge that allows the flange body to move from an open position to a closed position. The flange body defines an inner curved engagement surface that contacts an outer surface of the shaft when the shaft flange is positioned along the shaft and in a closed position.

The shaft flange of the second embodiment of the invention includes first and second nest ends that are spaced from each other when the shaft flange is in an open position. The first nest end includes a first attachment lip, while the second nest end includes a second attachment lip. Both the first and second attachment lips have width of approximately one-half the axial width of the flange portion of the shaft flange. When the shaft flange is moved to the closed position, the first and second attachment lips overlap each other.

When the shaft flange is in the closed position, a mechanical attachment member is positioned to extend between the first and second attachment lips to hold the shaft flange in the closed position. In one embodiment of the invention, the mechanical attachment member is a rivet, while other types of mechanical attachment means, such as Tox-Loc?, are contemplated as being within the scope of the invention.

The first and second attachment lips include an inner edge surface that is spaced radially from the outer surface of the shaft to which the flange is applied. The spacing between the shaft and the inner edge of each attachment lip provides additional room for utilizing the mechanical attachment member to hold the shaft flange in its closed position.Various other features, objects and advantages of the invention will be made apparent from the following description takentogether with the drawings.

Flange device and flange method with component protection

A flange device for roll-flange a rim of a component includes a flange head, a first flange roller which is mounted by the flange head and can be rolled off on the rim during roll-flange, and a second flange roller which is mounted by the flange head and forms a counter pressure roller for the first flange roller, the flange device including a stable protective structure which is or can be fastened to the component and forms a rolling surface for one of the flange rollers or supports a rolling surface.

A method for roll-flange a component along a flange edge, using a flange device according to claim 1, comprising the steps of: a) positioning the protective structure along the flange edge relative to the component; b) rolling thefirst flange roller off on a rim strip which extends along one side of the flange edge and is to be at least partially beaded around the flange edge; and c) rolling the second flange roller off on an area of the component which extends along theother side of the flange edge, the second flange roller acting as a counter pressure roller for the first flange roller; wherein one of the flange rollers rolls off on a rolling surface formed by the protective structure or on a rolling surfacesupported by the protective structure.

The situation presented, in which an outer part of the body has to be connected to an inner part by hemming, arises for example in the case of wheel arches of vehicle bodies. The outer shell of the body has a circular arced, preferablysemi-circular section, on the rim of which the so-called wheel arch is fastened on the inner side of the body. The problem here is that the outer side of the outer shell should not be deformed or at least deformed as little as possible, i.e. must notfor example receive any dents or scratches, since these would be immediately visible when the outer shell is subsequently painted, and would spoil the aesthetic effect which the vehicle body is intended to impart.

In principle, this therefore prohibits using hemming device comprising pressing and counter pressure rollers, since the counter pressure roller would then run along the outer side of the outer shell and could deform it. The solutions knownhitherto get by using sliders which are moved radially outwards behind the rim of the outer shell, with respect to the wheel section, and thus turn it inwards. Since a counter pressure is omitted here, the quality of the hem is not always satisfactory. Moreover, this is relatively involved equipment which only caters specifically for the body of one type of vehicle in each case, which makes using it in production facilities in which different types of body are built problematic.

The invention relates to a flange device for roll-flange a rim of a component or other work piece along a flange edge, and to a flange method. The flange device preferably forms a hemming device for producing a hem connection. Thecomponent is preferably a body part, as such or already assembled. The invention is then particularly advantageous if the body part forms a viewed area, for example an outer part of the body, in the subsequent finished product, preferably a vehicle.

The invention preferably relates to a device for hemming the rim of a first body part which preferably forms an outer side of a body, wherein the rim of a second body part which for example forms an inner part of the body lies in the hem slot ofthe first body part. The device comprises a flange head with at least one counter pressure roller supported on the outer side of the first body part and preferably at least two pressing rollers which oppose the counter pressure roller or each opposeone counter pressure roller, for successively turning over the rim of the first body part.

It is an object of the invention to turn over the rim of a component, preferably vehicle a body part and in particular an outer metal sheet, using simple means, such that the component is not deformed. The device should also be configured suchthat it can be quickly adapted to different component shapes.

The invention relates to a flange device comprising a flange head, at least one first flange roller and at least one second flange roller which are each pivoted by the flange head. In the case of roll-flange, the first flangeroller forms a pressing roller which rolls off on a rim to be beaded, preferably a narrow rim strip of the component. The second flange roller acts as a counter pressure roller for the first flange roller, i.e. it takes up the force to be applied bythe first flange roller in order to bead the rim strip by for example 30° or 45°. In accordance with their respective function, the first flange roller is referred to below as the pressing roller and the second flange roller isreferred to below as the counter pressure roller. The flange head can in particular be fastened to one end of a robot arm which preferably exhibits all six degrees of freedom of movement, but at least exhibits the degrees of freedom required for theflange process itself.

In accordance with the invention, the flange device further includes a stable protective structure which can be fastened to the component or is fastened during roll-flange. For the counter pressure roller, the protective structure eitherforms a rolling surface itself, on which the counter pressure roller rolls off during roll-flange, or it only forms the rolling surface indirectly, by supporting a rolling surface on which the counter pressure roller directly rolls off. In the firstcase, an inner side of the protective structure abuts the component and is preferably shaped so as to be adapted to its surface. An outer side of the protective structure forms the rolling surface for the counter pressure roller. In the second case,the protective structure is arranged in the inner region of the flange edge to be formed and abuts the inner side of the component, wherein the protective structure is preferably shaped so as to be adapted to the surface of the inner side. Because itis supported on the inner side, the component can itself form the rolling surface for the counter pressure roller in the second case and is nonetheless not deformed by the pressing counter pressure roller, or far less than without the support on theinner side.

If the protective structure forms the rolling surface itself, the counter pressure roller does not roll off directly on the component, but on the protective structure which preferably forms a sort of matrix which is adapted to the inner side ofthe outer contour of the component, such that even the smallest spatial configurations of the component can be exactly copied and deformations need not be feared. The flange head itself can be a standard type which can also be used for other flangeprocesses. Above all, this has the advantage that a number of different bodies can be processed for example on a production line for vehicle bodies, preferably automobile bodies. It is merely necessary to retain respectively adapted protectivestructures which can be initially placed onto the body or inserted in the inner region of the flange edge, before the flange process is started.

In preferred embodiments, the area of the protective structure with which the protective structure abuts the area to be protected is shaped so as to conform to said abutting area of the component, such that the protective structure and thecomponent abut full-face.

The bodies and the protective structure preferably each have at least one marker which allows the protective strip to be placed in an exact fit on the rim to be flanged over. The at least one marker on the body can be a contour or edge which isinherently predefined, such as sections for doors, beams or the like. At least one hole can also be specifically introduced. In preferred embodiments, the protective structure possesses a centring element, preferably a positioning pin, and at least onestopper element which is used as a contour abutment. Alternatively, the protective structure can also be provided with just two centring elements, preferably positioning pins, or with just two stopper elements. Using such pairs of positioning meanswhich co-operate with corresponding positioning means of the component or--in the assumed example--with the body, the protective structure is exactly positioned relative to the flange edge when it abuts the abutting area of the component. In thealternative embodiment, in which the protective structure is arranged in the inner region of the flange edge, a single positioning element--preferably a stopper element--can be sufficient for positioning.

In one development, the flange head mounts a third flange roller which forms another counter pressure roller for at least one of the first flange roller and the second flange roller in a flange process. A closed flow of force may beobtained by means of such a third flange roller. Such an embodiment is particularly advantageous for a protective structure arranged in the inner region of the flange edge. The third flange roller, acting as a suppressor, can also serve to fastenthe protective structure. Thus, in particular in a protective structure arranged in the inner region of the flange edge, an additional fastening can even be completely omitted. In principle, this also applies to a protective structure abutting on theoutside.

In another development, a sensing element is fastened to or formed on the flange head, preferably pivoted as a sensing roller, in addition to the at least two flange rollers, and the protective structure forms a guiding path for the sensingelement, preferably another rolling surface, which follows the course of the flange edge. The sensing element, which is guided on the guiding path along the flange edge in a flange process, in turn guides the flange head, enabling theexpenditure which has to be made for controlling the movements of the flange head, in particular the measuring expenditure, to be reduced. For roll-flange along the flange edge, it is in principle even possible to completely omit controlling orregulating on the basis of positional signals obtained by measurement. If the flange head is guided along the flange edge by means of a sensing element, by guiding the guiding element on a guiding cam which is preferably formed by the protectivestrip but could in principle for example also be formed by the flange edge itself, the flange head is preferably mounted such that it can move back and forth in a direction pointing at least substantially normally with respect to the guiding path,preferably against an elastic restoring force. The elastic restoring force can expediently be a pneumatic force.

Advantageously, a sensor, preferably a distance sensor, is provided. The sensor is preferably mounted on the flange head or a platform to which the flange head is fastened. By means of the sensor the distance between the flange head andthe component or the protective structure can be ascertained. The sensing element can be replaced by a distance sensor which operates without contact, by moving the distance sensor along the guiding path described with respect to the sensing elementduring roll-flange, constantly measuring the distance without contact, and using the readings to regulate the movement of the flange head. A 1D sensor is sufficient as the distance sensor.

In developments, a two-dimensional sensor is provided which operates without contact, i.e. a 2D sensor using which the position of the flange head relative to the component, in particular its flange edge, can be ascertained in a plane of viewonto the component. The 2D sensor is preferably mounted on the flange head or a platform to which the flange head is fastened. In the preferred application--roll-flange on a body part--the plane of view extends in the XZ plane of the usualco-ordinate system of vehicle bodies. This sensor system is only required, and in advantageous method embodiments also only used, to place the flange head for roll-flange on the flange edge. If a mechanical sensing element or the distance sensorcited is not provided, the 2D sensor or another substitute sensor system, for example two 1D sensors, can also be used to regulate the movements of the flange head during roll-flange. Preferably, however, the 2D sensor system is provided in additionto the sensing element or distance sensor cited. Sensing and regulating in the XZ plane is particularly advantageous for hemming a so-called drop flange.

If, however, it may be assumed that the components to be flange always assume the positionprovided for roll-flange with sufficient accuracy, and are themselves always shaped with sufficient accuracy, then a 2D sensor system can be omitted, since in this case, it is possible to rely on the fact that it is sufficient if the flange headmoves to a predefined position, for example a pre-programmed position. In the circumstances cited, the sensing element and the distance sensor can also be omitted.

Flange lubricator attachment to a composite brake shoe

A device for lubricating a flange portion of a railroad wheel attachable to a composition brake shoe. The device comprises at least one lubricating member formed from a polymer based compound selected from the group consisting of phenolic resins, epoxy resins, polyamides, polytetrafluoroethenes, and various combinations thereof. The lubricating member has a substantially flat first side engageable with a longitudinal flat surface of such composition brake shoe and a radially opposed second side that has a substantially flat portion for contacting such flange portion of such railroad wheel. The device further includes a means for attaching the lubricating member or members to such composition brake shoe.

Many railroad locomotives and cars use wheel tread braking which provides the braking effort required by forcing a brake shoe formed with a friction composition material against the tread of the steel wheel. Brake shoe engagement with the wheel tread produces friction that dissipates the energy of momentum in the form of heat. In order for such braking to be effective, however, wheel rotation is required. The adhesion due to the friction between the wheel tread and rail tends to maintain such wheel rotation as the brake shoe engages the wheel tread during a braking operation.

Excessive wheel wear and brake shoe change outs have been found to be cyclically high during the winter season. One theory attributes this, at least in part, to the more pronounced cleaning effect that the brake shoe has on the wheel as the result of higher moisture contact during wintertime. In that such cleaning action tends to increase the contact friction; or adhesion between the wheel and rail, increased contact stresses are created in the wheel. Such contact stresses being especially high during the guiding and steering action of the wheel set, particularly, when encountering track curvature. Similar problems of wear are also a concern with the flange portion of the wheel. These stresses can be reduced with lubrication.

Wayside lubricators have been a part of railroading for many years. These are placed in curved territory to reduce wheel and flange wear particularly where the wear is the greatest on the curved portions of the track. Emphasis has shifted in recent years to on board lubricators which are locomotive mounted units that are designed to provide lubrication on tangent track as well as in the curved territory in an effort both to reduce wear and also to improve fuel consumption.

Thus, the railroad industry is constantly trying to find methods and/or equipment that can be used to reduce the wear that occurs on both the wheel surface that contacts the rail and also the flange portion and at the same time possibly decrease fuel consumption by providing improved lubricity.

The present invention provides a device for lubricating a flange portion of a railroad wheel attachable to a composition brake shoe. The device comprises at least one lubricating member formed from a polymer based compound selected from the group consisting of phenolic resins, epoxy resins, polyamides, polytetrafluoroethenes, and various combinations thereof. The at least one lubricating member has a first predetermined shape, wherein the first predetermined shape has a substantially flat first side engageable with a longitudinal flat surface of such composition brake shoe and a radially opposed second side that has a substantially flat portion for contacting such flange portion of such railroad wheel and a substantially arcuate portion for contacting the arcuate interface of such flange portion and a tread portion of such railroad wheel. The device further includes a means for attaching the lubricating member or members to such composition brake shoe.

In another embodiment of the invention a device is in combination with a brake block of a railway vehicle having a backing plate and a brake lining affixed to said backing plate and further having a braking surface engageable with a wheel tread of a wheel of such railway vehicle, said brake lining formed from a predetermined composition material. The improvement comprises the device for lubricating a flange portion of such railroad wheel. The device is attachable to the brake lining of such brake block. The device comprises at least one lubricating member formed from a polymer based compound selected from the group consisting of phenolic resins, epoxy resins, polyamides, polytetrafluoroethenes, and various combinations thereof.

The at least one lubricating member has a first predetermined shape, wherein the first predetermined shape has a substantially flat first side engageable with a longitudinal flat surface of such composition brake shoe and a radially opposed second side that has a substantially flat portion for contacting such flange portion of such railroad wheel and a substantially arcuate portion for contacting the arcuate interface of such flange portion and a tread portion of such railroad wheel. The device further includes a means for attaching the lubricating member or members to such composition brake shoe.

Such lubricating member 20 when attached to the brake lining 6 will provide lubrication for the flange portion of the railroad wheel by transferring solid lubricant to the flange as wheel rotates and the flange comes in contact with the lubricating member 20. After the lubricating member has been worn away to the point where it no longer contacts the flange it can be discarded and replaced with a new lubricating member.

The main use of this flange lubricator is to transfer the polymer based compound onto the flange and vicinity of the flange of a railroad wheel used by all types of railway rolling stock. The deposit of the polymer compound alters the friction between the flange of the railway wheel and the rail, especially at track curvatures. The polymer based compound deposited on the flange will substantially minimize flange wear.

Hydraulic Flanged Tube and Four-Bolt Split Flange Type

Scope--This SAE Standard covers complete general and dimensional specifications for the flanged heads and split flange clamp halves applicable to four-bolt split flange type tube, pipe, and hose connections with appropriate references to the O-ring seals and attaching components used in their assembly. (See Figures 1 and 2.) Also included are recommended port dimensions and port design considerations.

The flanged heads specified are incorporated into fittings having suitable means for attachment of tubes, pipes, or hoses to provide connection ends. These connections are intended for application in hydraulic systems, on industrial and commercial products, where it is desired to avoid the use of threaded connections.

THE RATED WORKING PRESSURE OF A HOSE ASSEMBLY COMPRISING SAE J518 HOSE CONNECTIONS AND SAE J517 HOSE SHALL NOT EXCEED THE LOWER OF THE TWO WORKING PRESSURE RATED VALUES.

Flanged heads shall be as specified in Figure 3 and Table 1. Split flange clamp halves shall be as specified in Figure 4 and Table 1. Port dimensions and spacing shall be as specified in Figure 5 and Table 2.

O-ring seals, having nominal dimensions as indicated in Table 1, are used in conjunction with these connections. They shall conform to the seals specified in SAE J120, Table on Dimensions and Tolerances.

Bolts for use with these connections shall be of the sizes and lengths indicated in Table 1. They shall be of SAE Grade 5 material or better as specified in SAE J429. Socket head cap screws of SAE Grade 5 material or better are acceptable.

Lock washers, if used, shall be in accordance with the light spring lock washers specified in SAE J489, Dimensions of Light, Medium, Heavy, Extra Heavy, and Hi Collar Spring Lock Washers, and of sizes applicable to the corresponding bolts.

The following general specifications supplement the dimensional data contained in Table 1 with respect to all unspecified detail.

This specification covers the pipe material and wall thickness applicable to lap joint flange pipe ends, manufactured by a mechanical forming process.

The lap joint flange connection has been widely used for low-pressure systems in the marine, process piping, and similar industries.

The values stated in SI units are to be regarded as the standard. The values given in parentheses are for information only.

This Standard covers the complete general, dimensional, mechanical, and performance data for metric prevailing-torque hex nuts and hex flange nuts of property classes 5, 9, and 10 as defined in ASTM A563M.

The inclusion of dimensional data in this Standard is not intended to imply that all of the nut sizes in conjunction with the various options described herein are stock items. Consumers should consult with suppliers concerning lists of stock production prevailing-torque hex and hex flange nuts.