Planar Chain-Link Helices Using Rebound-Compensated Bending
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Solution Overview
Problem
Existing methods for producing helices for chain-link nets from high-tensile steel struggle with achieving planar helices with advantageous net properties due to rebounding effects, leading to suboptimal mesh formation and stability.
Innovation Solution
A method using a braiding knife assembly that compensates for the rebounding effects of high-tensile steel by bending helices in a way that centers their legs in a plane, with overbending and overcompressing techniques to achieve a precisely adjustable opening angle, resulting in a braiding knife assembly that produces planar helices with improved stability and mesh properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional braiding knives are used to bend high-tensile steel wires, then the wires exhibit rebounding effects that rotate the center points of legs out of plane, but achieving planar helices requires compensating for this rebounding which increases manufacturing complexity
Solution Approach 1:
The patent applies preliminary action by pre-compensating for the rebounding effect during the bending process. The braiding knife assembly is designed to overbend the wire by a predetermined angle that accounts for the expected rebound, ensuring the wire settles into the desired planar position after elastic recovery. This eliminates the need for post-bending adjustments while maintaining manufacturing simplicity.
Solution Approach 2:
The patent changes the bending angle parameter to compensate for rebounding. By increasing the bending angle beyond the nominal target angle (overbending), the wire's elastic recovery brings it back to the exact desired angle. The braiding knife assembly incorporates adjustable bending angles that can be calibrated based on the specific wire material properties and desired final geometry.
2Strength
If high-tensile steel is used to produce helices, then the material strength increases, but the rebounding effects become more pronounced leading to poor mesh formation
Solution Approach 1:
The patent applies preliminary anti-action by designing the braiding knife assembly to counteract the rebounding force before it can degrade the helix geometry. The assembly includes features such as increased bending radius, optimized knife geometry, and controlled bending speed that reduce the magnitude of rebounding. Additionally, the bending process applies sufficient force in advance to ensure the wire remains plastic-deformed rather than elastic, preventing rebound from affecting precision.
3Shape
If the bending process compensates for rebounding by overbending, then planar helices are achieved, but the manufacturing process becomes more complex requiring precise control
Solution Approach 1:
The patent applies self-service by designing the braiding knife assembly to automatically compensate for rebounding without requiring external control systems. The mechanical design incorporates built-in compliance and overbending mechanisms that self-adjust based on the wire's elastic properties. The assembly may include spring-loaded components or adjustable fixtures that automatically adapt to different wire batches, eliminating the need for automated sensing and control while maintaining consistent planarity.
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 method enables the production of helices with enhanced stability and elongation properties, allowing for the creation of chain-link nets with improved energy absorption and assembly efficiency, particularly suitable for applications like underground mining.
Implementation Method 1
the helices are bent in such a manner that they comprise at least a plurality of first legs, at least a plurality of second legs, as well as at least a plurality of bending regions
Implementation Method 2
the helices are produced from at least one longitudinal element having at least one wire that is at least partially made of a high-tensile steel
Data Source
AI summary
A method for producing helices for a chain-link net, said helices for forming the chain-link net being interconnected, and rotated into one another, wherein the helices are produced from at least one longitudinal element, in particular a single wire, a wire bundle, a wire strand, and/or a wire rope, with at least one wire being partially implemented from a high-tensile steel, and wherein the helices are bent so that they include a plurality of first legs, a plurality of second legs, and a plurality of bending regions that interconnect a first leg and a neighboring second leg, wherein the helices are bent, by a braiding knife assembly comprising at least one braiding knife, in such a manner that at least the center points of the first legs and/or at least the center points of the second legs of a completely bent helix each lie substantially in one plane respectively.