Diamond Wire Interruption Points Reinforcement
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Solution Overview
Problem
The existing methods for manufacturing diamond wires for cutting stone materials result in weak points at the interruption points where the steel cable strands are joined, leading to premature fraying and reduced working life due to high tension and wear, despite polymer coating and previous attempts to align interruptions with composite bush-and-bead elements.
Innovation Solution
The method involves distributing the interruption points along the steel cable and using reinforcing elements, such as woven or mesh materials, to cover and stabilize these points, which can be positioned either before or after splicing, and are securely fixed with plastic coating to enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If splicing technique is used to join cable ends to form a ring, then the diamond wire can be wound onto pulleys, but weak points are created at interruption points where strands are joined end-to-end
Solution Approach 1:
The patent applies preliminary action by positioning reinforcing elements at the interruption points before the splicing operation is completed. This ensures that the weak points are strengthened in advance, preventing fraying and breakage that would occur during subsequent use and winding operations.
Solution Approach 2:
The patent applies local quality by providing reinforcing elements only at specific locations (interruption points) rather than uniformly along the entire cable. This targeted approach strengthens the weak points without adding unnecessary weight or complexity to the entire structure.
2Reliability
If interruption points are aligned with composite bush-and-bead elements to protect them, then some protection is provided, but play between bush and cable allows relative movement and fraying
Solution Approach 1:
The patent applies local quality by implementing a second reinforcing element specifically at the interruption points, distinct from the first reinforcing element at the bush-and-bead elements. This localized reinforcement addresses the specific problem of relative movement and fraying at interruption points without affecting other parts of the cable.
Solution Approach 2:
The patent applies composite materials by using reinforcing elements made of materials with different properties than the steel cable strands. These reinforcing elements provide additional strength and stability, creating a composite structure that resists relative movement and fraying.
3Stability of the object's composition
If six outer strands are interwoven over three metres with end portions superimposed, then a continuous cable structure is formed, but the cut ends create preferential breakage points under tension and wear
Solution Approach 1:
The patent applies local quality by providing reinforcing elements specifically at the interruption points where cut ends are arranged end-to-end. This localized reinforcement strengthens these weak points without affecting the continuous structure of the rest of the cable, maintaining stability while improving strength at critical locations.
Solution Approach 2:
The patent applies preliminary action by positioning reinforcing elements at the interruption points before the cable is subjected to tension and wear during operation. This ensures that the weak points are strengthened in advance, preventing breakage that would occur during subsequent use.
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
This approach significantly increases the working life of the diamond wire by reducing the risk of breakage at interruption points and allows for easier implementation, even by unskilled personnel, with the reinforcing elements providing elasticity to accommodate cable movements.
Implementation Method 1
the polymer material is injected inside them, which covers the steel cable and penetrates deep into the small gap formed between cable and bushes so as to fix permanently the composite bush-and-bead elements to the steel cable
Implementation Method 2
the reinforcing elements providing elasticity to accommodate cable movements
Data Source
Figure 1~2
Figure 3~7
Figure 8~9
AI summary
A method for manufacturing a diamond wire (13) for cutting stone material, comprising the steps of: producing a plurality of composite bush-and-bead elements (22); inserting a steel cable (12) inside the plurality of composite bush-and-bead elements (22); splicing the two ends of the steel cable; and performing plastic-coating. The method is characterized in that it comprises a step where a reinforcing element (20) is positioned on at least one interruption point, said step being performed prior to the plastic-coating step.