High-Carbon Hexagonal Wire Netting That Resists Unbraiding
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Solution Overview
Problem
Existing wire netting solutions for protecting slopes and embankments have low tensile strength, leading to breakage and unbraiding under load, and existing manufacturing machines are limited to producing hexagonal netting with low carbon steel wires, unable to handle high carbon steel wires with higher tensile strength.
Innovation Solution
A hexagonal wire netting made of high carbon steel wires with a tensile strength of 1500-1900 MPa, braided in at least 1.5 folds to form meshes with a width-to-length ratio less than 0.75, using a device with straightening guides and a drum with specific detent elements to prevent unbraiding and enable pre-tensioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low carbon steel wires are used for manufacturing hexagonal wire netting, then the netting can be easily manufactured with existing machines, but the tensile strength is limited to 550-700 MPa and breaks under loads above 25-70 kN
Solution Approach 1:
The patent changes the material parameter from low carbon steel (550-700 MPa) to high carbon steel (1500-1900 MPa), fundamentally altering the tensile strength characteristic. This parameter change enables the netting to withstand loads of 100-200 kN while maintaining manufacturability through the described braiding process
Solution Approach 2:
The patent creates a composite structure through at least 1.5 fold braiding of high carbon steel wires, where the interlaced wires work together to distribute and withstand high loads. The braided configuration itself acts as a composite system that leverages the high strength of the individual wires
2Strength
If high carbon steel wires with tensile strength of 1500-1900 MPa are used, then the tensile strength and load resistance are significantly improved, but the wires are more brittle and break during the braiding process in existing machines
Solution Approach 1:
The patent introduces straightening guides that pre-straighten the high carbon steel wires before they enter the braiding spindles. This preliminary action eliminates bends and irregularities that would cause stress concentrations and breakage during the braiding process, ensuring reliable production of the high strength netting
Solution Approach 2:
The straightening guides act as intermediary devices between the wire feed and the braiding spindles. These guides mediate the transition of high carbon steel wires into the braiding process by preparing them in advance, preventing direct breakage that would occur without this intermediate preparation step
3Ease of manufacture
If the meshes have a width-to-length ratio close to square shape with short sides, then the netting can be manufactured on existing machines, but the high strength wires tend to break when twisted on such short length and transferred to the drum
Solution Approach 1:
The patent modifies the mesh geometry dynamically by setting the width-to-length ratio to less than 0.75, creating elongated hexagonal meshes rather than square shapes. This dynamic geometric adjustment provides sufficient wire length and reduced bending stress during the braiding and drum transfer processes, enabling the use of high strength wires without breakage
4Device complexity
If existing machines are used for manufacturing, then the manufacturing process is simple, but they are only suitable for low carbon steel wires and cannot produce hexagonal netting with high tensile strength
Solution Approach 1:
The patent segments the manufacturing machine into distinct functional modules: wire straightening guides positioned before the braiding spindles, and a drum with specifically arranged detent elements. This segmentation allows each component to be optimized independently - the guides prepare high carbon steel wires, the spindles braid them, and the drum receives the finished product, collectively enabling high strength netting production
Solution Approach 2:
The patent enhances the universality of the manufacturing machine by adding straightening guides and modifying drum detent arrangements, transforming it from a machine limited to low carbon steel into a multi-functional device capable of processing high carbon steel wires. The modified machine can now handle both wire types, with the straightening guides and adjusted drum configuration enabling high strength wire processing
Data Source
Figure 1
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AI summary
A hexagonal wire netting (7), a process for manufacturing such a wire netting and a device for manufacturing a hexagonal wire netting (7), the device comprising an assembly of tubes (5) for leading the wires (1) of which every other is twisted into a spiral shape, a spindle (6) assembly and a drum (8) receiving the wire netting (7), the drum (8) being provided with detent elements (21). Between each tube (5) leading the spirally twisted wire (1) and the cooperating spindle (6) a straightening guide (10, 10') is located having an inlet opening (13, 15) cooperating with the tube (5) and an outlet opening (12, 20) cooperating with the spindle (6). The detent elements (21) are arranged on the drum (8) in such a way that the produced wire netting (7) has meshes in which the proportion of the width (A) to the length (B) is less than 0,75.