Metal mesh winding systems and methods

Abstract

The innovative metal mesh winding system for winding two different metal meshes on a central winding drum, the two or more metal meshes being unrolled from two unrolling spools, the system being configured to control mesh alignment and mesh tension during winding in alternate layers of different meshes with different tension values for each type of the two meshes. The method for monitoring the tension value of each type of metal mesh involves unrolling two metal meshes from two unrolling spools using a controlled brake device. These meshes are then wound in alternate layers on a central roller. The tension value of each mesh is measured using a transducer in a plurality of roller devices. Finally, the tension value and alignment of the two metal meshes are controlled respectively through a logic control unit and safe manual operations.

Description

TITLEMETAL MESH WINDING SYSTEMS AND METHODSDESCRIPTIONTECHNICAL FIELD

[0001] The subject matter disclosed herein relates to a metal mesh winding system, able in particular to control a mesh alignment and a mesh tension uniformity throughout mesh width. The subject matter disclosed herein relates also to a corresponding winding method. A field of particular advantageous application of such system and method is carbon capture technology and its machines.BACKGROUND ART

[0002] In general, a metal mesh is created through the weaving of metal wires resulting in large-scale mesh products through specific technical methods.

[0003] However, some existing metal mesh production processes use a fixed winding device structure that cannot be quickly adjusted to accommodate different sizes of metal mesh. This leads to deviations in the metal mesh after winding and reduces its applicability. Additionally, these devices often make it inconvenient to unload the metal mesh after winding, presenting further limitations.

[0004] Winding two or more different kinds of metal meshes, with two independent tension values set for each type of mesh in alternate layers, and managing and strictly controlling the tension of each mesh is not possible with existing metal mesh machines.

[0005] Carbon capture is a critical technology in reducing greenhouse gasemissions from power plants and other industrial facilities. Metallic meshes used for CO2 capture are made of porous materials, such as metals or metal alloys, which have a mesh or very small pore structure. This porous structure provides a large surface area for the adsorption of CO2 molecules from the air or other emission sources.

[0006] Machines for CO2 adsorption devices made of mesh are designed to capture and retain carbon dioxide from the air or other sources. These devices use porous metal meshes that offer a large surface area for CO2 adsorption, making them very efficient.

[0007] The metal meshes can be created using various manufacturing methods, such as physical vapor deposition (PVD), chemical vapor deposition (CVD), 3D printing, or mechanical metalworking. These processes allow for the optimization of the porous structure of the meshes to maximize CO2 capture efficiency.

[0008] A patent document, JPH002241614, is known which describes a winding system for metal meshes, adaptable to winding different types of metal meshes using a winding drum and two unwinding spools. However, this system is not capable of actively controlling the alignment and tension of the meshes during winding, and therefore cannot allow the alternate winding of layers with different tension values for each type of mesh.

[0009] However, it is desirable to have a new winding device for metal mesh that is particularly suitable for carbon capture, effectively resolving the problems and able to control mesh alignment and mesh tension during winding in alternate layers of different meshes.SUMMARY

[0010] According to a first aspect, the subject-matter disclosed herein relates to an innovative metal mesh winding system for winding two different metal meshes on a central winding drum, the two or more metal meshes being unrolled from two unrolling spools, the system being configured to control mesh alignment and mesh tension during winding in alternate layers of different meshes with different tension values for each type of the two meshes. According to a second aspect, the subject-matter disclosed herein relates to an innovative method for monitoring the tension value of each type of metal mesh involves unrolling two metal meshes from two unrolling spools using a mesh tension electronic regulation device. These meshes are then wound in alternate layers on a central roller. The tension value of each mesh is measured using a transducer in a plurality of roller devices. Finally, the tension value is controlled through a logic control unit and alignment of the two metal meshes is controlled through safely manual operations.BRIEF DESCRIPTION OF THE DRAWINGS.

[0011] A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:Fig. 1 shows a perspective view of an embodiment of an innovative metal mesh winding system.Fig. 2 shows a section of the innovative metal mesh winding system of Fig. 1.Figg.3 e 4 show a perspective view of an embodiment of one of the unwindingunits of the innovative metal mesh winding system of Fig. 1.Fig.5 shows a flow chart of an embodiment of an innovative winding method.DETAILED DESCRIPTION OF EMBODIMENTS

[0012] The subject-matter disclosed herein relates to an innovative metal mesh winding system designed for winding two different metal meshes on a central winding drum. The two or more metal meshes are unrolled from two unrolling spools. The system is configured to control mesh alignment and mesh tension during winding in alternate layers of different meshes, with different tension values for each type of the two meshes.

[0013] The innovative metal mesh winding system primarily comprises two unwinding units, each of which includes: one of the unrolling spools, from which the metal mesh is unrolled; a controlled device connected to the unrolling spool, the controlled device is a mesh tension electronic regulation device, in particular the controlled device refers to a tension regulation device comprising a continuous brake and an electric motor, configured to maintain and adjust mesh tension during winding, which regulates the tension of the mesh during the unrolling process, an adjustment device for the lateral and angular adjustment of the unrolling spool, ensuring precise alignment of the mesh.

[0014] The system is designed to ensure that the metal meshes are wound onto the central winding drum in alternate layers, maintaining different tensions for each type of mesh. This approach ensures that the meshes are wound uniformly and stably, preventing deformation or breakage.

[0015] Additionally, the system includes a plurality of roller devicesassociated with the unrolling spools and the central winding drum. These roller devices are configured to guide the metal meshes and include transducers that continuously measure the tension of the meshes. The measurements from the transducers are used by a logic control unit to regulate the controlled brake devices, maintaining the mesh tension within the desired limits throughout the winding process.

[0016] Reference now will be made in detail to embodiments of the disclosure, an example of which is illustrated in the drawings. Each example is provided by way of explanation of the disclosure, not limitation of the disclosure. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present disclosure without departing from the scope or spirit of the disclosure. In the following description, similar reference numerals are used for the illustration of figures of the embodiments to indicate elements performing the same or similar functions. Moreover, for clarity of illustration, some references may be not repeated in all the figures.

[0017] In Figures 1 and 2 are schematically shown an embodiment of an innovative mesh winding system. The innovative mesh winding system is generally indicated with reference numeral 1000 in Fig. 1 and in Fig. 2. The innovative method for monitoring a value of tension for each type of metal mesh through a metal mesh winding system is generally indicated with reference numeral 2000 in Fig. 5. The innovative mesh winding system utilizes mesh of virtually any kind (metal but even non-mental material, plain or striped or waved, etc...).

[0018] Typically, with non-limiting reference to Fig. 1, Fig. 2 and Fig.5, the innovative metal mesh winding system 1000 for winding two different metal meshes 400 on a central winding drum 100, the two or more metal meshes being unrolled from two unrolling spools 210 , the system being configured to controlmesh alignment and mesh tension during winding in alternate layers of different meshes with different tension values for each type of the two meshes. Preferably the metal mesh 400 has width ranging from 100 mm to 900 mm.

[0019] According to the embodiment shown in Fig. 1 the metal mesh winding system comprises: two unwinding units 200; a plurality 300 of roller device; and a logic control unit.

[0020] With non limiting reference to Figures the at least one plurality 300 of roller device is associated to one of the unrolling spools 210 and to the central winding drum 100 configured to pass one of the two different metal meshes 400. Preferably the central winding drum 100 is fixed.

[0021] As shown in Fig.1 and Fig 3, each of two unwinding units 200 comprises: one of the unrolling spools 210; at least a mesh tension electronic regulation device 220 connected with the unrolling spool 210; an adjustment device 230 for lateral and angular adjustment of the unrolling spool 210.

[0022] Advantageously the logic control unit is configured to regulate at least the mesh tension electronic regulation device220 based on measurement of the at least one transducer.

[0023] Additionally, the central winding drum 100 comprises a central brake 110 and an electric motor 111. Therefore, the logic control unit is configurated to keep the central winding drum 100 and each unwinding unit 200 on brakes, and to perform manual operations without losing mesh tension.

[0024] In particular, at the end of the winding process, and by chance during the winding operation, it is necessary to perform manual operations (like, at the end, the fixing of the mesh to the drum structure) inside the safety fence without losing mesh tension (loosing mesh tension during winding would mean to start over the process); this capability is obtained through logic control unitthat keeps each unwinding unit 200 and the central winding drum 100 on brakes while the system is de-energized allowing operators to enter safely inside the protective fence.

[0025] Considering Fig. 3 and Fig. 4 the adjustment device 230 comprises: a linear guideway 231 for lateral adjustment of the unrolling spool 210; a rotating structure 232 for angular adjustment of the unrolling spool 210 with respect to the central winding drum 100; and first and second handwheels 250, 260 configured to adjust the unwinding of the unrolling spools 210.

[0026] Preferably , the linear guideway 231 is a sled and advantageously the unrolling spool 210 is mounted on the linear guideway 231 and on the rotating structure 232.

[0027] Fig. 2 shows for example and without limitation that the plurality 300 of roller device comprise three roller devices, in particular comprise a central roller 310.

[0028] Advantageously the central roller 310 is configurated with the at least one transducer, preferably load cell, to measure the tension value of one of the two different metal meshes 400 during winding of the two different metal meshes 400 as it passes through the plurality 300 of roller device.

[0029] In other word mesh tension control is achieved through the direct reading of the tension (mesh passes through the plurality 300 of roller device with the central one assembled on load cells) and the control, in closed loop, of a dedicated continuous brake that keeps the tension regardless winding speed and winding drum diameter; this system is implemented for both un-winding rollers.

[0030] It is to be noted that at least the mesh tension electronic regulation device220 comprises: a continuous brake 222 configurated to keep uniformitythe tension value of each metal mesh and an electric motor 221 for rewinding the mesh backwards if needed. Advantageously the electric motor 221 allows to set the initial tension before winding start and to wind back the mesh, on operator request, in case some adjustments are required.

[0031] The first handwheel 250 is configurated to get a lateral adjustment of the unrolling spool 210 through the linear guideway 231 and the second handwheel 260 is configured to get an angular adjustment of the unrolling spool 210 through the rotating structure 232.

[0032] Fig.5 illustrates a flow chart 2000 of an embodiment a method for monitoring a value of tension for each type of metal mesh through a metal mesh winding system. The flow chart has a start block 2100 and an end block 2700; the steps corresponding to block 2200 to block 2600 are typically repeated several times during monitoring of metal mesh winding system. According to an innovative method, the steps are:- unrolling 2200 two metal meshes from two unrolling spools through at least a mesh tension electronic regulation device;- winding 2300 on a central roller in alternate layers of two metal meshes, measuring 2400 a value of tension of each of two metal meshes through a transducer of a plurality of roller device;- controlling 2500 the value of tension of two metal meshes through the logic control unit and the meshes alignment through safely manual operations.

[0033] Further the method comprises the step of performing 2600 safely manual operations through a logic control unit to keep the central winding drum 100 and each unwinding unit 200 on brakes.

Claims

CLAIMS1. A metal mesh winding system (1000) for winding two different metal meshes (400) on a central winding drum (100), the two or more metal meshes being unrolled from two unrolling spools (210), the system being configured to control mesh alignment and mesh tension during winding in alternate layers of different meshes with different tension values for each type of the two meshes, wherein the metal mesh winding system (1000) comprises:- two unwinding units (200) wherein each of two unwinding units (200) comprises: one of the unrolling spools (210); at least a mesh tension electronic regulation device (220) connected with the unrolling spool (210); an adjustment device (230) for lateral and angular adjustment of the unrolling spool (210); a plurality of roller device (300) associated to one of the unrolling spools (210) and to the central winding drum (100) configured to pass one of the two different metal meshes (400); comprising at least a transducer configured to a measure a tension value of one of the two different metal meshes (400); a logic control unit configured to regulate at least the mesh tension electronic regulation device (220) based on measurement of the at least the transducer2. The system (1000) of claim 1, wherein the adjustment device (230) comprises: a linear guideway (231) for lateral adjustment of the unrolling spool (210); a rotating structure (232) for angular adjustment of the unrolling spool (210) with respect to the central winding drum (100); and first and second handwheels (250) and (260) configured to adjust the unwinding of the unrolling spools (210).-9-3. The system (1000) of claim 1, wherein the plurality (300) of roller device comprises a central roller (310) configurated with at least the transducer (320) to measure the tension value of one of the two different metal meshes (400) during winding of the two different metal meshes (400) as it passes through the plurality (300) of roller device.

4. The system (1000) of claim 1, wherein the plurality (300) roller device comprise three roller devices.

5. The system (1000) of claim 1, wherein the transducer is a load cell.

6. The system (1000) of claim 1, wherein at least the mesh tension electronic regulation device (220) comprises: a continuous brake (222) configurated to keep uniformity the tension value of each metal mesh, and an electric motor (221), for rewinding the mesh backwards if needed.

7. The system (1000) of claim 1, wherein the unrolling spool (210) is mounted on the linear guideway (231) and on the rotating structure (232).

8. The system (1000) of claim 1, wherein the first handwheel (250) is configurated to get a lateral and adjustment of the unrolling spool (210) through the linear guideway (231)9. The system (1000) of claim 1, wherein the second handwheel (260) is configurated to get an angular adjustment of the unrolling spool (210) through the rotating structure (232).

10. The system (1000) of claim 1, wherein the winding drum (100) is fixed.

11. The system (1000) of claim 1, wherein the central winding drum (100) comprises a central brake (110) and an electric motor (111).

12. The system (1000) of claim 1, wherein the logic control unit isconfigurated to keep the central winding drum (100) and each unwinding unit (200) on brakes, and in order to allow to perform manual operations without losing mesh tension.

13. The system (1000) of claim 1, wherein the metal mesh (400) has width ranging from 100 mm to 900 mm.

14. A method (2000) for monitoring a value of tension for each type of metal mesh through a metal mesh winding system according to any one of claims 1 to 13, comprising the steps of- unrolling (2200) two metal meshes from the two unrolling spools through the respective mesh tension electronic regulation device;- winding (2300) on the central roller in alternate layers of two metal meshes; measuring (2400) a value of tension of each of two metal meshes through a transducer of the respective one of the plurality of roller device;- controlling (2500) the value of tension of the two metal meshes through a logic control unit and the meshes alignment through safely manual operations.

15. The method (2000) of claim 14, comprising further the steps of performing (2600) safely manual operations through the logic control unit to keep the central winding drum (100) and each unwinding unit (200) on brakes-11-

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