Polygonal Wire Loop Layout for Octagonal Container Packing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wire packaging methods result in wire settling and tangling during shipment due to gaps between cylindrical wire coils and octagonal liners, leading to inefficient use of space and operational issues during welding operations.
Innovation Solution
A container with a polygonal liner and a wire coiling apparatus that forms wire loops arrayed polygonally along the vertical walls, using an X-Y table to move the container and laying head in linear directions to minimize gaps and ensure tight packing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cylindrical wire loops are arranged in a circular pattern within an octagonal liner, then the container can accommodate standard circular coiling equipment, but gaps form between the wire loops and the octagonal liner walls causing wire settling and tangling
Solution Approach 1:
The patent changes the wire loop arrangement from a symmetric circular pattern to an asymmetric polygonal pattern that matches the octagonal liner geometry. This allows the wire loops to conform to the non-circular container walls, eliminating gaps and preventing wire settling while remaining compatible with standard coiling equipment through adaptive laying techniques.
Solution Approach 2:
The patent applies different arrangement patterns to different regions of the container. Wire loops are arranged polygonally along the vertical walls of the octagonal liner, creating tight local packing that conforms to the specific geometry of each wall section, rather than using a uniform circular pattern throughout.
2Productivity
If cylindrical wire coils are packed into the container, then the packing process is simple and fast, but the wire density is low and settling occurs during shipment
Solution Approach 1:
The patent employs a dynamic wire laying process where the coiling equipment adapts its motion pattern to create polygonal loops. The laying head moves in coordinated X-Y directions to form loops that match the octagonal geometry, allowing tight packing to be achieved automatically during the high-speed coiling process without requiring post-packing adjustments.
Solution Approach 2:
The patent changes the geometric parameters of the wire loop arrangement from circular to polygonal, and adjusts the loop dimensions and spacing to optimize density. By modifying the laying pattern parameters to match the container geometry, the system achieves higher wire density while maintaining efficient packaging speeds.
3Reliability
If the container is made taller to prevent wire settling, then wire stability is improved, but the storage efficiency and space utilization decrease
Solution Approach 1:
The patent applies preliminary action by pre-configuring the wire loop geometry and arrangement pattern to match the octagonal liner before the wire is even placed in the container. The polygonal arrangement is built-in during the coiling process, creating inherent stability that prevents settling without requiring additional vertical space or post-packing support structures.
Data Source
AI summary
A container includes an outer box, and a polygonal liner located within the outer box. The polygonal liner has a plurality of vertical walls. A continuous length of wire is located within the polygonal liner and forms a plurality of layers. Each of the layers is comprised of a series of wire loops arrayed polygonally along the vertical walls of the polygonal liner.