Apparatus for making border wire

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Solution Overview

Problem

The existing methods for making border wires with a rectangular cross-section are inefficient and require manual mechanical adjustments, leading to longer setup times and increased scrap metal, whereas automated solutions for circular cross-section wires are lacking.

Innovation Solution

A method and apparatus that unwind wire with a circular cross-section, straighten it using a three-axis straightener, and then pass it through a metal forming machine to create a rectangular cross-section, followed by cutting and bending into a rectangular configuration, with servo motors and welding to form a border wire, utilizing contact and non-contact detection systems for precision and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual mechanical adjustments are used to straighten wire with rectangular cross-section, then the apparatus can process rectangular wire, but the setup time increases and productivity decreases

Engineering Contradiction:

Improveability to process rectangular cross-section wireVSAvoidsetup time and production speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical adjustment systems with an automated servo motor-driven straightening system. The servo motors electronically control the straightening apparatus, eliminating the need for manual mechanical adjustments and enabling rapid adaptation to rectangular cross-section wire while maintaining high productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The straightening apparatus is designed to automatically detect and adapt to the wire geometry through servo-controlled mechanisms. The system performs self-adjustment without external intervention, allowing it to handle rectangular cross-section wire efficiently without increasing setup time.

Inventive Principle:

Principle #25Self-service

2Ease of manufacture

If conventional methods are used to make border wires, then the process is simpler, but scrap metal increases and efficiency decreases

Engineering Contradiction:

Improveprocess simplicityVSAvoidscrap metal

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent employs computer-controlled servo motors and automated detection systems to precisely control the wire forming process. This automation enables precise cutting and forming operations that minimize material waste while maintaining ease of manufacture through automated programming and control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system incorporates detection systems that provide feedback on wire position, geometry, and forming progress. This feedback enables real-time adjustments to minimize scrap metal generation while maintaining simple automated operation through closed-loop control.

Inventive Principle:

Principle #23Feedback

3Productivity

If automated servo motor systems are used to straighten rectangular wire, then setup time decreases and productivity increases, but device complexity increases

Engineering Contradiction:

Improvesetup speed and production efficiencyVSAvoidautomation system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The servo motor-driven straightening system is designed to handle multiple wire geometries (circular and rectangular cross-sections) using the same automated apparatus. This multi-functionality justifies the increased device complexity by eliminating the need for separate specialized equipment for different wire types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system uses programmable servo motors that can electronically adjust parameters such as straightening force, speed, and positioning based on the detected wire geometry. This parametric control enables high productivity through software configuration rather than physical reconfiguration, making the complexity manageable.

Inventive Principle:

Principle #35Parameter changes

4Strength

If rectangular cross-section wire is used for border wires, then the structural performance improves, but the straightening process becomes more difficult

Engineering Contradiction:

Improveborder wire structural performanceVSAvoidstraightening process difficulty

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent replaces traditional mechanical straightening mechanisms with servo motor-driven systems that provide precise, programmable control over the straightening process. This substitution enables the handling of rectangular cross-section wire, which has superior structural performance, while maintaining ease of operation through automated control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9895739B2Apparatus for making border wire

Publication Date: 2018.02.20 L & P PROPERTY MANAGEMENT CO

AI summary

An apparatus is provided which makes a border wire having a rectangular cross-section. The apparatus is adapted to receive a roll of wire having a circular cross-section, straighten the wire and change the cross-section of the wire to rectangular. The reconfigured wire is then accumulated, passed through another straightener, cut to size and then bent into a rectangular configuration. Opposed ends of the piece of wire having a rectangular cross-section are welded together to complete the border wire. The apparatus has an ejector which removes the completed border wire from the apparatus.