Metal Mesh Reinforcement Feed and Welding for Continuous Size Change
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machines for producing metal mesh reinforcements from metal profiles require significant time and personnel to adjust for different reinforcement sizes, leading to process interruptions and susceptibility to faults due to manual handling of winding profiles and welding unit adjustments.
Innovation Solution
A machine with a remote cutting arrangement and synchronized feed and welding units allows for automatic change of winding profiles, maintaining continuous production by moving the winding profile to the welding unit and adjusting the welding unit's position to accommodate varying external dimensions, reducing manual intervention and increasing automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of welding unit and loading of coiled profiles is used, then machine can process different reinforcement sizes, but significant time and personnel are required leading to process interruptions
Solution Approach 1:
The welding unit is made movable along the longitudinal axis of the longitudinal profiles, allowing dynamic adjustment of its position to accommodate different reinforcement outer dimensions. This dynamic positioning enables the welding unit to adapt to various product specifications without requiring complete machine reconfiguration, thereby maintaining versatility while reducing adjustment time and minimizing production interruptions.
2Adaptability or versatility
If coiled profiles with different diameters are processed regularly, then various reinforcement types can be manufactured, but corresponding interruptions occur in production process
Solution Approach 1:
The coiled profiles are pre-loaded onto the drum in advance before the actual production process begins. This preliminary loading allows multiple coiled profiles of different diameters to be prepared and positioned ahead of time, so that during production, the system can switch between different profile types without interruption. The feed unit is also pre-configured to handle different profile diameters, enabling seamless transitions between reinforcement types.
3Extent of automation
If automatic handling of winding profiles is implemented, then personnel requirements are minimized, but machine complexity increases
Solution Approach 1:
The feed unit is designed to automatically feed sections of the coiled profile to the welding unit without requiring manual intervention. The cutting device automatically separates profile sections at predetermined lengths, and the feed unit automatically transports these sections to the welding position. This self-service automation reduces personnel requirements while the modular design of these automated components helps manage overall machine complexity by using standardized, interchangeable units.
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 solution significantly reduces production time, minimizes personnel requirements, and minimizes process interruptions by enabling automatic handling of winding profiles and precise welding unit positioning, enhancing the efficiency and reliability of metal mesh reinforcement production.
Implementation Method 1
a welding unit for welding a longitudinal profile to the coiled profile at a connection point of the two metal profiles
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a device (2) for producing a metal mesh reinforcement from metal profiles that are joined together, wherein the metal mesh reinforcement comprises a plurality of long profiles (4) and a winding profile (3), wherein the device (2) comprises a welding unit (14) for welding a longitudinal profile (4) to a winding profile (3) at a joint node of the two metal profiles and a feed unit (17) for feeding a portion of the winding profile (3) provided from a master to the welding unit (14), wherein the feed unit (17) comprises a cutting arrangement (19) for cutting the winding profile (3), to cut a profile portion of the winding profile (3) from the master. According to the invention, the cutting arrangement (19) is arranged within a cutting zone of the device (2) remote from the welding unit (14), the device (2) is designed such that, after cutting of the winding profile (3), the end portion of the winding profile (3) cut from the master is fed from the cutting zone to the welding unit (14) and at least one further weld is made between the cut-off end portion of the winding profile (3) and a longitudinal profile (4), to produce the metal mesh reinforcement.