Double-Wire Fence Panel Welding for Straightness and Faster Production
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Solution Overview
Problem
Existing welding processes for fence panels result in reduced straightness due to wire bending and are time-consuming, as they typically involve welding longitudinal wires one by one to a transverse wire, allowing for relative movement and causing warping.
Innovation Solution
Simultaneously welding all points of contact of a transverse bar with longitudinal bars using the 'cascade' method, ensuring that all longitudinal bars are welded to a transverse bar at once to maintain straightness and efficiency, particularly for double-wire fence panels with 51 longitudinal bars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cascade welding is used to weld longitudinal wires one by one to a transverse wire, then the wires can move relative to each other during welding, but the fence panels are obtained with reduced straightness due to wire bending and warping
Solution Approach 1:
The patent merges multiple welding operations into a single simultaneous welding step. All longitudinal bars are welded to the transverse bar at the same time rather than sequentially, which prevents the warping and bending that occurs when wires move relative to each other during sequential welding. This combining of operations resolves the contradiction by maintaining both manufacturing feasibility and straightness precision.
Solution Approach 2:
The patent applies dynamic control by using a moving welding gun that welds all longitudinal bars simultaneously while traversing across them. The synchronized movement of the welding gun and the simultaneous activation of multiple welding points creates a dynamic welding process that maintains bar alignment and prevents warping, thereby preserving straightness while enabling efficient manufacturing.
2Ease of manufacture
If cascade welding is used to weld longitudinal wires one by one, then relative movement is allowed during welding, but the process becomes time-consuming
Solution Approach 1:
The patent combines multiple sequential welding operations into a single simultaneous welding step. By welding all longitudinal bars to the transverse bar at the same time using a multi-spot welding machine with multiple electrodes or a moving welding gun, the total production time is dramatically reduced while maintaining the flexibility to handle different fence panel configurations.
Solution Approach 2:
The patent implements continuous welding action by using a moving welding gun that continuously traverses across all longitudinal bars while simultaneously welding them. This continuous process eliminates the start-stop nature of sequential welding, maintaining productive action throughout the entire welding cycle and significantly increasing production efficiency.
3Manufacturing precision
If all points of contact are welded simultaneously, then straightness is improved, but the device complexity increases
Solution Approach 1:
The patent uses a moving welding gun that dynamically traverses across the longitudinal bars while simultaneously welding them. This dynamic approach allows a single welding device to perform multiple welding operations at different positions at the same time, achieving simultaneous welding of all contact points without requiring a complex multi-electrode apparatus stationary at each position.
Solution Approach 2:
The welding gun is designed with multi-functionality, capable of welding multiple longitudinal bars simultaneously through a single device. The gun can be positioned and oriented to weld across the entire width of the fence panel, making a single device perform the work of multiple welding stations, thereby reducing overall system complexity while achieving simultaneous welding.
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 method produces fence panels with minimized horizontal and vertical deflection, ensuring improved straightness and reducing production time, crucial for maintaining a straight multi-panel fence structure.
Implementation Method 1
simultaneous welding of all points of contact of a transverse bar to the longitudinal bars
Data Source
Figure 1
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AI summary
A method of welding bars into an improved double-wire fence panel, comprising the steps of: (i) supplying and positioning 51 metal longitudinal bars to a welding apparatus, where the metal longitudinal bars are positioned parallel, and where the distance between two adjacent longitudinal bars is 40-60 mm c.t.c., (ii) supplying and positioning two metal transverse bars at the welding apparatus, where the transverse bars touch the longitudinal bars perpendicularly, so that each longitudinal bar has one point of contact with each transverse bar, and where a first transverse bar is supplied at the top of a plane formed by the parallel longitudinal bars and a second transverse bar is supplied at the bottom of the plane, so that an opposing pair of transverse bars is formed, (iii) the simultaneous welding of the points of contact of a transverse bar to the 51 longitudinal bars, (iv) repeating steps ii and iii, whereby a fence panel is obtained, wherein the resulting fence panel has a maximum horizontal deflection of between -10 and 10 mm.