Conveyor Wheel Chain Welding Without a Chain Turner
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Solution Overview
Problem
Conventional chain welding processes are complex and inefficient, particularly when using a chain turner, which complicates the handling of chain links in different orientations, leading to increased contamination risk and mechanical stress on the chain.
Innovation Solution
A method utilizing a conveyor wheel to guide and position chain links for welding, allowing relative displacement between the conveyor wheel and welding device to facilitate welding of both standing and lying links in a single tool, reducing contamination and mechanical stress, and using a double chain wheel design to efficiently manage chain alignment and rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a chain turner is used to rotate the chain after each weld, then both rows of chains can be welded directly one after the other, but the device complexity and cost increase significantly
Solution Approach 1:
Instead of rotating the chain to bring different orientations to a fixed welding position, the invention inverts the approach by moving the welding device to different positions relative to the chain. The welding device translates between a first position for welding horizontal links and a second position for welding vertical links, eliminating the need for chain rotation mechanisms.
Solution Approach 2:
The welding device is designed with multi-functionality to weld chain links in both horizontal and vertical orientations using the same device. By incorporating translation mechanisms that allow the welding device to access different positions, a single device performs what previously required multiple devices or complex rotation mechanisms.
2Device complexity
If the chain is welded completely on horizontal links in a first pass and then on vertical links in a second pass, then the device complexity is reduced, but the processing time doubles
Solution Approach 1:
The welding process achieves continuity by allowing alternating welding of horizontal and vertical links in a single pass. The welding device translates between positions to access different link orientations sequentially, maintaining continuous productive action without requiring the chain to be repositioned or the process to be interrupted for a second pass.
Solution Approach 2:
The welding device incorporates dynamic translation capability to move between different positions during the welding process. This dynamic positioning allows the device to adapt to different link orientations (horizontal and vertical) sequentially, enabling continuous welding in a single pass rather than requiring static positioning and multiple passes.
3Loss of time
If two chain welding machines are used in series to weld the chain in a single pass, then the processing time is reduced, but the cost and complexity increase
Solution Approach 1:
The welding device achieves multi-functionality by incorporating translation mechanisms that enable a single device to weld both horizontal and vertical links. This eliminates the need for two separate chain welding machines used in series, reducing overall system complexity and cost while maintaining single-pass welding capability.
Solution Approach 2:
The invention merges the functionality of two separate welding machines into a single device. By combining the welding capability for both horizontal and vertical links in one device with translation capability, the system achieves what previously required two machines, reducing complexity while maintaining productivity.
4Adaptability or versatility
If conventional chain welding processes are used with chain turners, then both orientations can be welded, but the susceptibility to contamination increases
Solution Approach 1:
The invention extracts and eliminates the chain turner mechanism from the welding system. By removing the rotation component that required the chain to be manipulated and repositioned, the system reduces the opportunities for contamination during handling while maintaining the capability to weld both horizontal and vertical links through welding device translation.
Data Source
Figure 1~1a
Figure 2~3
Figure 4~5
AI summary
A method and apparatus for chain welding of a chain (2) starting from a chain of open chain links in a C-shape use a conveyor wheel (6) to guide and transport the chain. The conveyor wheel temporarily receives one or more chain links and positions them for welding. Preferably, the conveyor wheel (6) is designed as a double sprocket, in each of whose two pocket wheels one chain link from two chain strands (22, 24) is temporarily received.In each pass for welding a chain link, the conveyor wheel is moved relative to a welding device (4) transversely to the longitudinal direction of the chain guided in the conveyor wheel and then assumes a welding position in which a chain link to be welded, positioned in the conveyor wheel, faces the welding device and its open ends are welded; afterwards, the conveyor wheel is moved out of the welding position and rotated to transport the chain in order to bring the next chain link to be welded into the welding position. This pass is repeated for the individual chain links, whereby in the double sprocket, chain links of the two chain runs (22, 24) can be welded alternately.