Flat Wire Netting Coils Through Springback-Compensated Bending
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Solution Overview
Problem
Existing methods for producing coils from high-strength steel struggle with springback effects, leading to helixes that do not lie in a plane, which affects the quality and efficiency of wire mesh production.
Innovation Solution
A method and device using a weaving knife arrangement to bend helixes such that their centers lie in a plane, compensating for springback effects by overbending and adjusting the opening angle, allowing for the production of flat helixes made of high-strength steel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bending methods are used on high-strength steel wire, then the wire can be formed into helixes, but springback effects cause the helix centers to rotate out of plane, resulting in non-planar geometry
Solution Approach 1:
The patent applies preliminary action by pre-bending the wire beyond the desired final angle (overbending) to compensate for the anticipated springback effect. The bending device is configured to bend the wire to an intermediate angle that is more acute than the target angle, so that when springback occurs, the wire settles at the correct final angle with centers remaining in plane.
Solution Approach 2:
The patent changes the bending parameters by adjusting the bending angle and applying multiple bending stages. The bending device can apply different bending angles in sequence, and adjust the opening angle of the helix, to achieve the desired planar configuration after springback occurs in high-strength steel wire.
2Strength
If high-strength steel wire is used to improve wire mesh strength, then energy absorption and stability are enhanced, but springback effects increase making it difficult to produce planar helixes
Solution Approach 1:
The bending device performs preliminary overbending to counteract the increased springback characteristic of high-strength steel. By bending the wire to an intermediate angle that exceeds the desired final angle, the device ensures that after springback, the helix achieves the correct planar geometry despite the material's resistance to deformation.
Solution Approach 2:
The patent adjusts bending parameters including the intermediate bending angle and opening angle to accommodate high-strength steel properties. The device can vary these parameters to optimize the bending process for high-strength materials, making production of planar helixes feasible despite increased springback effects.
3Manufacturing precision
If the wire is bent to compensate for springback by overbending, then planar helixes can be achieved, but the bending process becomes more complex requiring adjustable opening angles
Solution Approach 1:
The bending device implements preliminary overbending through a configured intermediate bending step. The device geometry is designed to automatically apply the appropriate overbending angle, and can adjust the opening angle as needed, to ensure planar helix centers in the final product while managing the complexity through structured design.
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
Enables the production of wire mesh with improved stability, energy absorption, and installation speed by ensuring helixes lie in a plane, compensating for springback and achieving precise adjustable angles.
Implementation Method 1
springback effects of the high-strength steel
Implementation Method 2
springback, in particular elastic deformation, of the wire of the helixes
Data Source
Figure 1~3
Figure 4~6
Figure 7a
AI summary
The invention is based on a method for producing coils (10a-g, 102a-g) for a wire netting (12a-g), which are intended to be connected to one another, in particular to be twisted in one another, to form the wire netting (12a-g), wherein the coils (10a-g, 102a-g) are produced from at least one longitudinal element (14a-g), in particular a single wire, a wire bundle, a wire strand and/or a wire cable, comprising at least one wire (30a-g) formed at least partially from a high-strength steel, and wherein the coils (10a-g, 102a-g) are bent in such a way that they comprise at least a plurality of first legs (16a-g), at least a plurality of second legs (18a-g) and also at least a plurality of bending points (20a-g) connecting a first leg (16a-g) and an adjacent second leg (18a-g) to one another. It is proposed that the coils (10a-g, 102a-g) are bent by a braid cutter assembly (24a-g), having at least one braid cutter (22a-g), in such a way that at least the midpoints (26 a-g) of the first legs (16a-g) and/or at least the midpoints (28a-g) of the second legs (18a-g) of a finished bent coil (10a-g, 102a-g) lie in each case at least substantially in one plane.