Curved Welded Wire Mesh Production Using Pulling Feeding
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Solution Overview
Problem
Existing methods for producing curved welded wire mesh suffer from inaccuracies due to relative positioning errors and accumulation of errors during the welding process, leading to increased production time and complexity in changing over to new mesh types, as they rely on pushing mechanisms that are inflexible and prone to slippage.
Innovation Solution
The method involves pulling longitudinal rods using a pulling device driven in both longitudinal and transverse directions, with a detachable gripping mechanism and control device, allowing for precise positioning and easy switching between different mesh types, thereby eliminating positioning errors and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pushing mechanisms (feed tongs or feed rollers) are used to advance longitudinal rods, then the welding process can proceed, but relative positioning errors occur and positioning errors accumulate due to gripping or slippage, leading to large inaccuracy in arc-shaped reinforcing steel mats
Solution Approach 1:
Instead of pushing the longitudinal rods forward using feed tongs or rollers, the invention pulls the longitudinal rods backward toward the welding position. This inversion of the feeding direction eliminates the gripping and slippage problems associated with pushing mechanisms, as the rods are pulled firmly by the welding head itself, ensuring accurate positioning without accumulation of errors
Solution Approach 2:
The welding head performs dual functions: it welds the transverse rod to the longitudinal rods and simultaneously feeds the longitudinal rods for the next welding position. The welding head pulls the longitudinal rods backward to the required position after each weld, eliminating the need for separate feeding mechanisms and ensuring that positioning is integrated with the welding process itself
2Manufacturing precision
If feed distance for each longitudinal bar is set individually to reduce inaccuracy, then positioning precision improves, but production time increases significantly due to complicated readjustments during welding
Solution Approach 1:
The invention changes the control parameter from individual bar positioning to continuous feed distance control. By controlling the pull distance of the welding head in a continuous manner rather than adjusting each bar individually, the system achieves accurate arc-shaped mat production without requiring repeated readjustments during the welding process
Solution Approach 2:
The welding head continuously pulls the longitudinal rods backward to the required position after each weld without interruption or readjustment. This continuous feeding action maintains welding continuity and eliminates the time-consuming individual bar positioning adjustments, ensuring both precision and productivity
3Manufacturing precision
If a swivel arm is used for pulling feed, then positioning errors are reduced, but the flexibility of the manufacturing process is severely restricted and arc radius cannot be changed during production
Solution Approach 1:
The welding head is designed with dynamic positioning capability, allowing it to move not only backward for feeding but also laterally to adjust the arc radius. This dynamic flexibility enables changeover to different mesh types and arc radii during production, unlike the fixed pivot point of a swivel arm
Solution Approach 2:
The welding head serves multiple functions: welding, pulling feed, and adjusting arc radius. This multi-functionality allows the same device to produce different types of arc-shaped reinforcing steel mats with varying radii without requiring separate dedicated mechanisms for each function
4Productivity
If pushing mechanisms are used to advance longitudinal rods, then the welding process can continue, but the system is inflexible and prone to slippage, requiring complicated readjustments
Solution Approach 1:
The invention inverts the feeding mechanism from pushing to pulling. The welding head pulls the longitudinal rods backward firmly, eliminating slippage and the need for complicated readjustments, while maintaining continuous welding process
Data Source
Figure 1
Figure 2a~2c
Figure 3
AI summary
The method involves welding multiple rods to a structure made of multiple longitudinal rods (2) and transverse rods (3). An advancement takes place over a traction device (6) by using a train, and is driven in the longitudinal direction (L) and transverse direction (Q). The advancement is carried out at a welded transverse rod (3'), and is rotated in a plane of a wire mesh (1). The train is formed at the welded transverse rods or longitudinal rods (2'), and is releasably attached to the traction device. Independent claims are included for the following: (1) a method for producing a three dimensional truncated cone-shaped reinforcement for concrete components; and (2) an apparatus for manufacturing curved wire mesh.