Border Wire Forming with Automated Straightening and Welding
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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 wire straightening are lacking.
Innovation Solution
A method and apparatus that involves unwinding wire with a circular cross-section, passing it through a metal forming machine to create a rectangular cross-section, using a three-axis straightener, cutting to a predetermined length, bending into a rectangular configuration, and welding the ends, with servo motors and contact/non-contact detection systems for precise and quick production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual mechanical adjustments are used for wire straightening, then device complexity is reduced, but productivity decreases and loss of time increases
Solution Approach 1:
The patent replaces manual mechanical adjustment systems with an automated wire straightening apparatus that uses mechanical rollers and guides to automatically straighten wire during the forming process. This substitution eliminates the need for operators to manually adjust machinery, thereby increasing productivity while maintaining manageable device complexity through standardized mechanical components.
Solution Approach 2:
The wire straightening apparatus performs preliminary straightening of the wire before it reaches the forming dies. By pre-straightening the wire in advance, the system prevents bending and misalignment issues during the forming process, reducing the need for rework and scrap metal, thus improving productivity without significantly increasing device complexity.
2Loss of time
If automated servo motor systems are used for wire straightening, then productivity increases and loss of time decreases, but device complexity increases
Solution Approach 1:
The patent employs servo motors to control the wire straightening apparatus, replacing manual mechanical adjustment systems. The servo motors enable automated, precise control of the straightening rollers and guides, allowing rapid setup changes and consistent performance. This automation reduces setup time and eliminates manual intervention, improving productivity while the modular design keeps device complexity manageable.
3Manufacturing precision
If conventional wire straightening methods are used, then device complexity is minimized, but manufacturing precision decreases and scrap metal increases
Solution Approach 1:
The wire straightening apparatus performs preliminary straightening of the wire before it enters the forming dies. By pre-straightening the wire in advance, the system ensures that the wire is properly aligned and free of bends before forming operations begin. This preliminary action significantly improves manufacturing precision of the final product and reduces scrap metal caused by misalignment, while the apparatus complexity remains moderate through the use of standard mechanical components.
Solution Approach 2:
The patent incorporates detection systems that monitor the wire's position and straightness in real-time during the forming process. This feedback mechanism allows the control system to make automatic adjustments to the wire feed rate and straightening roller positions, ensuring consistent manufacturing precision. The feedback loop improves precision without requiring overly complex apparatus by using simple sensors and control algorithms.
Data Source
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.