Double Pocket Wheel Chain Welding for Single-Pass Throughput
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional chain welding methods are laborious and complex, particularly when using a chain turner, and require multiple passes or machines to efficiently handle and weld both horizontal and vertical chain links.
Innovation Solution
A method and apparatus utilizing a conveying wheel, such as a pocket wheel, to guide and position chain links for welding, allowing for simultaneous welding of vertical and horizontal links in a single tool, with the wheel's rotational movement enabling cyclic advancement and reducing mechanical loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a chain turner is used to rotate the non-welded chain after each welding operation, then the welding process can continue with the next chain link, but the device complexity and labor intensity increase significantly
Solution Approach 1:
Instead of rotating the chain to bring the next link into position, the invention rotates the welding device itself around the stationary chain. This inversion of the moving element simplifies the mechanism by eliminating the complex chain turner while maintaining continuous welding capability.
Solution Approach 2:
The welding device is designed to perform multiple functions: it welds the current link and then rotates to position itself for the next link. This multi-functionality eliminates the need for separate chain rotation mechanisms, reducing overall device complexity while maintaining productivity.
2Ease of manufacture
If the chain is welded completely at horizontal links in a first pass and then at vertical links in a second pass, then the welding process is simplified, but the throughput time increases due to multiple passes
Solution Approach 1:
The welding device continuously welds chain links without interruption by rotating around the chain. After welding a horizontal link, the device simply rotates to position itself for the next link, whether horizontal or vertical, eliminating idle time between passes and maintaining continuous productive action.
Solution Approach 2:
The welding device transitions from a static position to a dynamic rotating position between welding operations. This dynamic movement allows the device to access both horizontal and vertical links in sequence, enabling single-pass welding of all orientations without the time loss associated with multiple static passes.
3Productivity
If two chain-welding machines are lined up one behind the other to weld the chain in one pass, then the throughput time is reduced, but the device complexity and cost increase
Solution Approach 1:
A single welding device is designed to perform the work of multiple machines by rotating around the chain and welding links of all orientations. This universal device consolidates the functionality of two separate machines into one, reducing complexity and cost while maintaining high throughput.
Solution Approach 2:
The invention merges the welding functions for both horizontal and vertical links into a single welding device that operates continuously. By combining these functions in one device rather than using two separate machines, the system achieves the throughput benefits of multiple machines without their associated complexity and cost.
Data Source
AI summary
A method and an apparatus for chain welding a chain starting from a chain composed of open C-shaped chain links uses a conveying wheel which receives one or more chain links of the chain and positions them for welding. The conveying wheel is a double chain wheel, the two pocket wheels of which receive a respective chain link of two chain strands of the chain. In each sequence of welding of a chain link, the conveying wheel is displaced relative to a welding device transversely with respect to the longitudinal direction of the chain and then occupies a welding position in which a chain link to be welded, as chain link that is vertical in the conveying wheel, faces the welding device and the open ends thereof are welded. This sequence is repeated, allowing that chain links of the two chain strands are alternately welded in the chain wheel.