Net Welding Electrode Speed Zoning for Precise Wire Joining
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Solution Overview
Problem
Existing welding machines for producing net structures face challenges in achieving accurate and reliable welding of longitudinal and transverse wires due to high-speed pneumatic or hydraulic actuators, leading to wire deformation and limited control over the welding process, especially in fine-meshed structures with thin wires.
Innovation Solution
A welding machine equipped with electrical actuators and a control unit that divides the movement distance into two speed regimes, with a higher speed regime covering 95% of the distance and a lower speed regime covering 5%, allowing for precise control and reduced wire deformation, along with a wire supply apparatus for accurate positioning and gripping of wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pneumatic or hydraulic actuators are used to drive welding electrodes at high speed, then productivity is improved, but manufacturing precision deteriorates due to wire deformation and displacement
Solution Approach 1:
The movement of the welding electrode is divided into multiple speed regimes (first speed regime with higher speed, second speed regime with lower speed) along the movement path. This segmentation allows the electrode to travel fast over most of the distance while slowing down near the welding point to prevent wire deformation, thus resolving the contradiction between productivity and manufacturing precision.
2Productivity
If high-speed actuation is used to increase welding productivity, then production efficiency is improved, but welding quality deteriorates due to limited control and hammer effect
Solution Approach 1:
The actuator system dynamically adjusts its speed during the welding electrode's movement, transitioning from a first speed regime to a second speed regime based on the electrode's position relative to the welding point. This dynamic speed adjustment ensures both high productivity and consistent weld quality by preventing the hammer effect while maintaining efficient cycling.
Solution Approach 2:
The control unit monitors the position of the welding electrode and adjusts the actuator speed accordingly, creating a feedback mechanism that ensures the electrode arrives at the welding point with appropriate speed control. This feedback system maintains weld quality consistency while preserving high productivity.
3Productivity
If the welding electrode moves at constant high speed, then productivity is improved, but manufacturing precision deteriorates due to inability to control welding depth and positioning accuracy
Solution Approach 1:
The electrode movement path is segmented into different speed zones: a first speed regime for traversing most of the distance at high speed, and a second speed regime for the final approach to the welding point. This segmentation enables both high productivity and precise control of welding depth and positioning accuracy.
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
The solution enables reliable and accurate welding of longitudinal and transverse wires, reducing the risk of defects and deformation, and improving the overall quality of the net structure by allowing for precise control of the welding process and wire positioning.
Implementation Method 1
The welding electrode is moved from a waiting position to a welding position at a first speed regime and from the welding position to the waiting position at a second speed regime, wherein the first speed regime corresponds to at least 90% of a total distance and the second speed regime corresponds to at most 10% of the total distance
Data Source
Figure 1
AI summary
The present invention relates to methods and means for the production of net structures consisting of a plurality of longitudinal wires and transverse wires which are welded together, such as nets, grids, fences and the like by means of a welding machine which comprises at least one welding electrode driven by at least one electrical actuator. The method comprises moving the welding electrode from a waiting position to a welding position at the welding point and the moving in step is carried out in at least two speed regimes, in particular at least one higher and at least one lower speed regime. The higher speed regime starts from the waiting position and corresponds to at least 95% of the total distance which is defined as the distance between the waiting position and the welding position and the lower speed regime runs up to the welding position and corresponds to at most 5% of the total distance. The average speed of the welding electrode in the higher speed regime is higher than the average speed in the lower speed regime.