Metal Basket Manufacturing via Grid Frame Bending
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Solution Overview
Problem
Conventional metal basket manufacturing is complex and costly due to the crisscross stacking and welding of multiple metal bars, which complicates the process and increases production expenses.
Innovation Solution
A method involving initial welding of first and second metal bars to form a grid frame, followed by bending and finish welding to create a holder, simplifying the process and reducing costs by using peripheral bars with bending extensions to form the basket's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple first metal bars and multiple second metal bars are stacked crisscross and welded together to form the body, then the basket structure is formed, but the manufacturing process becomes complicated and production cost increases
Solution Approach 1:
The invention merges the holder formation process into the body bending process. The peripheral bars are welded to the surrounding grids before bending, and the bending operation simultaneously forms both the body structure and the holder structure. This combines what would traditionally be separate assembly operations into a single integrated process, reducing manufacturing complexity and cost.
Solution Approach 2:
The peripheral bars are preliminarily welded to the surrounding grids in the initial welding step, creating bending extensions that will later form the holder. This preliminary attachment allows the holder to be formed during the bending operation rather than requiring separate holder fabrication and assembly steps, simplifying the overall manufacturing process.
2Ease of manufacture
If the holder is bent from a metal rod and fitted with the opening of the body, then the holder is formed, but the manufacturing process becomes more complex
Solution Approach 1:
The invention combines holder formation with the body bending operation. The peripheral bars with bending extensions are welded to the surrounding grids, and when the grid frame is bent to form the body, the bending extensions are simultaneously bent and connected to form the holder. This merges two separate manufacturing operations into one, improving production efficiency.
Solution Approach 2:
The bending extensions are preliminarily prepared as part of the peripheral bars during initial welding. This preliminary preparation allows the holder to be formed automatically during the bending operation without requiring separate holder fabrication, thus improving productivity.
3Ease of manufacture
If multiple first metal bars and multiple second metal bars are stacked crisscross and welded together, then the grid frame is formed, but the production cost increases
Solution Approach 1:
The invention merges the holder formation into the body bending process, eliminating the need for separate holder fabrication and assembly. This reduces the number of welding operations and material requirements, thereby reducing production cost while maintaining structural integrity through the integrated design.
Solution Approach 2:
The peripheral bars are preliminarily welded to the surrounding grids with bending extensions that will form the holder. This preliminary action ensures proper positioning and structural integrity during the bending process while reducing overall material consumption and production cost.
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 simplifies the manufacturing process, reduces production costs, and enhances market competitiveness by streamlining the assembly of metal baskets while maintaining structural integrity.
Implementation Method 1
the multiple first metal bars and the multiple second metal bars are stacked crisscross and are welded together to form a grid frame
Implementation Method 2
the two bending extensions of each peripheral bar and the body are bent and are connected together to produce a holder
Data Source
AI summary
A method of manufacturing a metal basket contains the steps of preparing materials, initial welding, bending, and finish welding. In a step of preparing materials, multiple first metal bars, multiple second metal bars, and at least two peripheral bars are provided. In a step of initial welding, the multiple first metal bars and the multiple second metal bars are stacked crisscross and are welded together to produce a grid frame which has a base and multiple surrounding grids, and the at least two peripheral bars are welded with the multiple surrounding grids respectively. In a step of bending, the grid frame and the multiple surrounding grids are bent, such that the multiple surrounding grids are bent upwardly and are perpendicular to the base. In a step of finish welding, the at least two peripheral bars are welded together.