MACHINE FOR CHAIN LINKAGE COMPONENTS

This invention relates to a machine regarding serial production of oval metal ring for locking mechanism.

Carabiner may be defined as an oval metal ring which enables any load bearing rope or line to be linked in a fast and practical manner. The area of use of carabiner shows variety in our country and the world. In Turkey it is commonly used particularly in mountaineering, livestock, fire fighting, marine, transportation, civil defense, automotive, military, bag, leather areas. Carabiner is among those items that we import most. Especially China plays a deterrent role in carabiner production since it challenges the competition force of the local investors. If a serial production band is created with an efficient R&D substructure also by considering the customer requests, a sustainable competition environment could be achieved. Thus, an original product/ product range will be obtained by having its whole technology is developed in our country and a potential export item will be created.

Our country has known and been using the carabiner for more than fifteen years. But this product cannot be produced in our country, but being imported. It causes a serious foreign currency loss due to the increase of the use area and popularization with each passing day. Although the use of the mentioned product in our country exceeds 100 million pieces, there has been no R&D based production study till today. All these developments requires R& D studies in carabiner production and use where there has been no technological infrastructure created yet in our country. This project aims the development of the carabiner production technology by using the potential of our country.

Carabiner production is made by passing through many processes by using various apparatus on each part manually and by various patterns connected to presses. Such production will cause the increase of the costs in Turkey conditions. Within the project that we will carry out, the machines suitable for the materials to be produced which will process the parts of the carabiner automatically in fast manner will be built and the batch amounts will be increased, costs will be reduced. The serial production line to be realized within the scope of the project will work with coiled rolled material instead of the material with certain length. This will prevent the waste that can come out from the lengths of the material. The basic items found in the carabiner production: (1) Carabiner body cutting and folding machine, (2) Body channels and dents opening machine, (3) Latch tip opening machine, (4) Spring hole, channel and dent opening machine, (5) Final forming machine, (6) Assembly presses and drilling machine. Since these machinery and equipment are in special production, their design and manufacture will be performed via service purchase. By means of the serial production line, the carabiner test production will be carried out in accordance with the national and international standards. It is aimed that all designs of the created serial production line and the product itself to be performed in line with the updated technological data and to obtain an original design. An original model and production substructure belong to our country will be created. Thus, an original product will be obtained by having its whole technology is developed in our country and a potential export item will be created. Moreover, with the carabiner serial production project, our country will have the chance to compete with strong competitors. In light with the market research, with the serial production in Turkey of the carabiner product range which is used a wide are from civil defense to livestock, space studies, a serious contribution and employment opportunity will be made to the economy. The results to b obtained from these studies are considered not to be limited to the design and manufacture of only one product, but to be leading to the designs of idifferent purpose tools. Thus, a product will be obtained by having its whole technology is developed in our country and a potential export item will be created. As a conclusion, this project aims the development of the carabiner production technology by using the potential of our country.

Carabiner production is made by passing through many processes by using various apparatus on each part manually and by various patterns connected to presses. Such production will cause the increase of the costs in Turkey conditions. Within the project that we will carry out, the machines suitable for the materials to be produced which will process the parts of the carabiner automatically in fast manner will be built and the batch amounts will be increased, costs will be reduced. The serial production line to be realized within the scope of the project will work with coiled rolled material instead of the material with certain length. This will eliminate the wastes to come out (at the beginning and the end) from the lengths of the materials and it will minimize the cost per product by reducing the raw material loss. Besides, each of other machines in this group will perform three to four processes at the same time uninterruptedly and increase the production number and minimize the production cost per item. These performed studies can be explained as the development and application of new techniques for the purpose of obtaining cost reducing and standard increasing results. In addition, regarding to the production, the method will be improved. As a conclusion, an original model and production substructure belong to our country will be created. Thus, an original product will be obtained by having its whole technology is developed in our country and a potential export item will be created.

The market use of carabiner as the product mentioned in the project includes as semifinished and finished material in various sectors. Therefore, the merchantability potential is quite high. It is a product having an economical value. In case to cover the market demand domestically for this product which currently is imported intensively, the import of labor force in the product sector will be prevented. Thus, the product will cease to be a fully imported product and the market need will be significantly covered from domestic market.

The basic items specified above are listed below:

a. Body forming machine (carabiner body cutting and folding machine): It is a hydraulic and mechanic running machine which passes the cold rolled coiled wire in special size through straightening rollers, pulls the material length required to be folded, cuts it, makes the first folding and takes it on the cast and repeats this process ten or twenty times per minute. The command system is designed as electronically. b. Body channels and dents opening machine: It is an electro-pneumatic command machine which opens the channels and dents on the body by means of circular saw and knife fixed at motor tips and rotates on certain times, continues to work without stopping by processing at each station on the materials over the transfer template. c. Latch tip opening machine (dent opening): It is an electro-mechanic commanded machine which makes uninterrupted fast forming process on the parts placed in the slots of the turning cast on the machine by means of straight and tapered circular saws via a reducer motor. d. Spring hole, channel and dent opening machine: It is an electro-pneumatic machine with four processes which opens latch spring hole, rivet hole dent and channel on the carabiner. e. Final forming template: The final forming template takes the aligned body parts of the carabiner having the channels opened, makes the final formation by means of cylinders and repeats this process; after the final forming pattern, the product goes to the assembly. f. Assembly: The assembly is made in one ton pressing machine having rivet heading templates which is used in the assembly of the carabiner, all parts which is being processed.

This invention consists of body forming machine (telform), body channels and dents opening machine, fairlead opening machine (latch machine), spring hole, channel and dent opening machine (latch machine), double sided dent opening machine (latch machine).

The invention is elucidated with attached figures whereas :

Figure 1 - Body forming machine view,

Figure 2a - Body channels and dents opening machine upper view,

Figure 2b - Body channels and dents opening machine side view, Figure 3a- Latch machine (fairlead opening) upper view, Figure 3b- Latch machine (fairlead opening) side view, Figure 4a- Latch machine (spring hole, channel and dent opening) upper view, Figure 4b- Latch machine (spring hole, channel and dent opening) side view, Figure 5a- Latch machine (double side dent opening) upper view, Figure 5b- Latch machine (double side dent opening) side view,

The parts depicted in the above figures are itemized below:

1) Main body

2) Transfer group 3) Cooling water distributor

4) Cooling water tank and motor

5) Main board

6) Command board

7) Main distribution board 8) Air tank

9) Vertical dent milling cutter 10) Horizontal channel milling cutter 11) Horizontal dent milling cutter 12)Transfer lock 13)Transfer driver

14) Graded channel milling cutter 15) Vertical drill 16)Thrust

17)Transfer reducer and motor 18) Vertical milling cutter 19) Vertical milling cutter bearing

20)Clamping stopper 21)Measure completer 22)Graded milling cutter 23) Horizontal drill 24)Channel milling cutter

25) Double blade channel opening milling cutter 26) Driver reducer and motor 27)Transfer chain bearing 28)Transfer chain

Body forming machine:

It is a mechanical machine which runs by an electrical motor. The machine takes the coiled wire, straighten it through eight straightening rollers, pulls it in desired length via claw slide, brings it over the cutting ring and forming template and pauses. During this pause, the cutting blade and the male pattern at the same time get downs in a certain tonnage and cuts the wire. The wire stays in between two template and takes the first shape in the template and continues to pause under the same press. During this pause, the templates defined as finger affixed at the tips of two arms on this machine press on the wire, makes the final forming, returns back and the other male template returns back to former position and stands there. During this pause, the other template goes into the bearing, drops the formed wire on it and completed the process, and it is a continuously running machine that repeats this process sixty three times per minute.

In order to reduce the wear of slides and bearings on the machine, it is being supported by automatic greasing system. The motions at the machine are enabled to be made in different time intervals via a heavy wheel and cams.

Body channels and dents opening machine:

The machine runs by the combination of three systems. These systems are mechanical, pneumatic and electronic. The machine consists of one main body (1) and transfer group (2) on this body, cooling water distributor (3), cooling water tank and motor (4), main board (5), command board (6), main distribution board (7), air tank (8), vertical dent milling cutter (9), horizontal channel milling cutter (10), horizontal dent milling cutter (11), transfer lock (12), transfer driver (13), graded channel milling cutter (14), vertical drill (15).

The carabiner body coming out of body forming machine is placed in the bearing on the transfer group (2) on the machine body. There are eight bearings on the transfer (2).

When the machine is started, the transfer group (2) turns and brings the placed material first in front of the vertical dent milling (9) and locks it. The vertical dent milling cutter (9) takes chops simultaneously from upper and lower part of the material via circular knives and returns back to former position. Transfer (2) moves again, initially placed material comes in front of the horizontal dent milling (11) and lock again. In the mean time, it is continued to put material on transfer (2). When the vertical dent milling cutter (9) and horizontal dent milling cutter (11) make their processes and returns to starting point, transfer (2) moves again and the initially placed material comes in front of the vertical drill (15) and it is locked. When the vertical dent milling cutter (9), horizontal dent milling cutter (11) and the vertical drill (15) make their processes and returns to starting point, transfer (2) turns again and the initially placed material comes in front of the graded channel milling cutter (14) and it is locked. When the vertical dent milling cutter (9), horizontal dent milling cutter (11), the vertical drill (15) and graded channel milling cutter (14) make their processes and returns to starting point, transfer (2) turns again and comes in front of the horizontal channel milling cutter (10) and it is locked. When the horizontal channel milling cutter (10) starts processing, dent milling cutter (9), horizontal dent milling cutter (11), the vertical drill (15) and graded channel milling cutter (14) also start processing. When the processing is completed and return back to the starting point, transfer (2) repeats the mentioned processes without stopping and each time the completed material is taken from the transfer (2). When cutting process is performed, the cooling water is given on cutter knives and the cutting life is extended. In order to proceed with these processes, pneumatic cylinders are being used whereas PNC is utilized via sensors in command processes. PNC uses a software program for process series and durations.

The machine performs horizontal channel, vertical dent, vertical drill, graded channel, horizontal dent and transfer turning processes that is; seven processes simultaneously. Thus, it is labor and time saving. Latch Machine (Fairlead opening):

Mechanic and electric motors driven this latch opening machine consists of main body (1), transfer group (2), cooling water distributor (3), cooling water tank and motor (4), command board (6), thrust (16), transfer reducer and motor (17), vertical milling cutter (18), vertical milling cutter bearing (19), clamp fixer (20), measure completer (21), graded milling cutter (22).

Straight wires cut in certain measures, materials aligned on the bearings in transfer group (2) turning in slow rpm initially pass through the measure completer (21). Accordingly, while passing through vertical milling cutter (18), the circular knife takes chops, shaves the half of the material in certain amount, passes by scraping the thrust (16). This scraping makes the material turns and comes to graded milling cutter (22). The graded milling cutter (22) takes chops in an angle and completes the fairlead. In order not to blind the cutter knives, the cooling water is given over the knives and their life is extended. These processes continue in the transfer group (2) without stopping and it can produce 20-30 pieces/minute according to material thickness.

The machine makes four processes simultaneously on various size materials passing through transfer (2), measure completer (21), vertical milling cutter (18), graded milling cutter (22) and saves up time.

Latch Machine (Spring hole, channel and dent opening): It works mechanically, pneumatically and electronically. Main parts connected to the body; main body (1), transfer group (2), cooling water distributor (3), cooling water tank and motor (4), main board (5), command board (6), main distribution board (7), air tank (8), vertical dent milling cutter (9), transfer lock (12), transfer driver (13), vertical drill (15), clamp fixer (20), measure completer (21), horizontal drill (23), channel milling cutter (24).

Materials processed in the latch machine are placed on slots at the transfer group (2).

When these placed materials come in front of the vertical dent milling cutter (9) by turning of the transfer (2), it locks and performs the cutting process. Meanwhile, the material is continued to be put on the transfer (2). Transfer (2) moves again, comes in front of the channel dent milling (24) and the transfer (2) is locked again. Meanwhile the material also comes in front of the horizontal dent milling cutter (9). Upon both milling cutters (9, 24) make their processes and returns back to the starting point, transfer (2) moves again; initially placed material comes in front of the vertical drill (15) and the transfer (2) is locked. Meanwhile the material comes also in front of the vertical dent milling cutter (9) and the channel milling cutter (24) and all of them make the cutting process at the same time. Upon their return back to the starting point, transfer (2) moves again; initially placed material comes in front of the horizontal drill (23) and the transfer (2) is locked. Therefore material comes in front of all milling cutters (9, 24, 15 and 23) and they all function simultaneously. By repeating these motions continuously, each time one completed material is taken from the transfer (2).

Pneumatic cylinders and programmable electronic circuits (PNC) are used for making these processes and movements. The cooling water is fed on the knives and the life of the knives and drill tips is extended.

The machine makes six processes at the same time by performing transfer (2), vertical dent milling cutter (9), channel milling cutter (24), vertical drill (15), horizontal drill (23) and by locking the transfer lock (12).

Latch Machine (double sided dent opening):

The machine rotates in a certain speed uninterruptedly via mechanical and electrical motors and makes the cutting process quickly. Opening dent at the tip of the latch at both sides simultaneously is made here.

Main parts found on the machine: main body (1), cooling water distributor (3), cooling water tank and motor (4), main board (5), double blade channel opening cutter (25), driver reducer and motor (26), transfer chain bearing (27), transfer chain (28).

The material comes out of the latch machine (spring hole, channel and dent opening) is placed continuously within the dies on the transfer chain (28). After the transfer chain

(28) goes into the transfer chain bearing (27), it passes between two blades of double blade channel opening cutter (25), the channel is opened at the same time in both sides of the latch and taken out from the die in the transfer chain by means of the further apparatus and the process is completed. It performs this process without stopping. It makes the cooling process by giving the cooling water on cutting knives. By giving cooling water onto the transfer chain (28) from lower part, the incoming chops are washed over the dies and chains.