Automated Reinforcement Wire Binding for Stable Non-Welded Joints
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Solution Overview
Problem
Existing reinforcement devices, such as cage welding machines, suffer from material loss and reduced stability at welding points due to resistance welding, making them unsuitable for earthquake zones or marine environments.
Innovation Solution
A device with automated positioning mechanisms for longitudinal and cross wires, using a binding unit with a binding element to connect wires at precise points, allowing for varied wire diameters and cross-sectional shapes, and incorporating a welding system for secure reinforcement production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If resistance welding is used to join winding wire to longitudinal wire, then welding speed and productivity are improved, but material loss occurs at the joining location and stability of the reinforcing body is weakened
Solution Approach 1:
The harmful effect of material loss during resistance welding is eliminated by extracting the welding process from the joining method options and replacing it with binding. The binding unit applies binding elements that secure the intersection without removing material from the wires themselves.
Solution Approach 2:
A binding element acts as an intermediary between the winding wire and longitudinal wire, providing the joining function without directly affecting the wire material. This mediator (binding element) secures the intersection while preserving the integrity and stability of the reinforcing body.
2Strength
If resistance welding is used to connect wires, then joining strength is improved, but the reinforcement becomes unsuitable for earthquake zones and marine environments
Solution Approach 1:
The joining method is changed from a permanent thermal process (welding) to a mechanical binding process. This parameter change in the joining approach allows the reinforcement to maintain flexibility and integrity under seismic and marine conditions, where thermal welding creates vulnerable points.
3Manufacturing precision
If automated positioning mechanisms are implemented, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The positioning mechanisms serve multiple functions: they position the binding point, guide the binding element, and coordinate the binding operation. This multi-functionality reduces the need for separate specialized components, thereby managing device complexity while achieving high positioning precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enhances production efficiency and stability by minimizing material loss, enabling the creation of robust reinforcements suitable for diverse applications, including earthquake zones and marine environments, with reduced production time and increased durability.
Implementation Method 1
the known cage welding machine comprises a resistance welding system, thereby achieving comparatively short cycle times
Implementation Method 2
welds a winding wire, which extends helically around longitudinal wires of the reinforcing body, at a point of intersection of the winding wire and of a longitudinal wire by means of a welding method
Data Source
AI summary
A device for producing a reinforcement, wherein the device has positioning mechanisms for the automated positioning of a longitudinal wire and a cross wire of the reinforcement to be produced. The device is characterized in that the device has a binding unit, wherein the device is designed to automatically connect the positioned wires by way of a binding element at a binding point by means of the binding unit.