Pivoting Cross-Wire Feeder for Low-Downtime Mesh Welding
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Solution Overview
Problem
Existing methods for producing fence mats with cross wires above or below longitudinal wires result in inefficient production due to increased downtime, complex electrical drive technology, additional space requirements, and high maintenance and setup costs, particularly when cross-wire diameter and length change.
Innovation Solution
A lower cross-wire storage device is provided with a pivoting upper cross-wire feeder that can switch between positions for filling and supplying cross wires, allowing efficient use of downtimes for magazine filling and reducing the need for additional equipment and space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two cross-wire magazines are arranged (one above and one below/to the side of the production line) to enable manufacturing of double-rod fence mats, then production capability is improved, but device complexity, space requirements, and maintenance costs increase
Solution Approach 1:
The upper cross-wire feeder is designed to perform multiple functions: it serves as both a cross-wire magazine for direct supply to the production line and a filling station for the lower cross-wire storage device. This multi-functionality eliminates the need for a separate second magazine, reducing device complexity while maintaining the capability to produce double-rod fence mats
Solution Approach 2:
The invention merges the functions of two separate cross-wire magazines into a single upper feeder system that can both supply cross-wires to the production line and refill the lower storage device. This consolidation reduces the number of components, simplifies the system, and lowers maintenance requirements while preserving full production capability
2Reliability
If cross-wires are supplied from a cross-wire magazine separated from the bundle or fed by an inline wire straightening system, then cross-wire supply is ensured, but production downtime increases due to frequent refilling
Solution Approach 1:
The lower cross-wire storage device is pre-filled during production downtime or before production starts. The upper feeder can refill this lower storage device during brief pauses, ensuring that cross-wires are always available and preventing production stoppages due to empty magazines
Solution Approach 2:
The lower cross-wire storage device acts as an intermediary buffer between the upper feeder and the production line. It stores a reserve of cross-wires, allowing the production line to continue operating even when the upper feeder needs to be refilled or maintained, thus maintaining both reliability and productivity
3Adaptability or versatility
If cross-wire diameter and length changes are required, then product versatility is improved, but setup costs and time increase due to needing to retrofit two magazines
Solution Approach 1:
Since there is only one upper cross-wire feeder instead of two magazines, changing cross-wire specifications requires adjusting only a single device rather than retrofitting two separate magazines. This significantly reduces setup time and costs while maintaining the ability to produce different fence mat variants
Solution Approach 2:
The system is designed to be dynamically adjustable, allowing quick changes in cross-wire diameter and length parameters. The single upper feeder can be reconfigured for different wire specifications without the complexity of coordinating changes across multiple magazines, enabling rapid adaptation to different product requirements
4Area of stationary object
If a cross-wire magazine is arranged below and to the side of the production line, then space utilization is improved, but additional electrical drive technology and complex control systems are required
Solution Approach 1:
The invention extracts the lower cross-wire storage device from the complex electrical drive system and positions it directly below the production line, fed by a simple mechanical feeder from above. This eliminates the need for complex electrical drives and control systems while maintaining efficient space utilization
Solution Approach 2:
The complex electrical drive technology is replaced with a simple mechanical feeding system where the upper cross-wire feeder mechanically supplies cross-wires to the lower storage device through gravity or simple mechanical conveyance. This substitution dramatically simplifies the system while maintaining compact space utilization
Data Source
AI summary
A device for feeding transverse wires above and below a production line for mesh mats which consist of welded transverse and longitudinal wires, said device comprising an upper transverse wire feeder, which has a guide channel and which is arranged in a first position, in which transverse wires are fed along the guide channel of the production line, and comprising a lower transverse wire feeder, by means of which transverse wires can be conveyed from below to the production line, wherein a lower transverse wire store is provided, from which transverse wires can be removed by the lower transverse wire feeder, and wherein the upper transverse wire feeder is designed as a transverse wire switch, which can be pivoted at least into a second position, wherein the lower transverse wire store can be loaded with transverse wired by the transverse wire switch in the second position.