Automatic Plant Support Forming Machine Integration
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Solution Overview
Problem
The existing production process for plant growth supports requires multiple facilities and manual operation, resulting in high economic and labor costs due to the need for separate machines for rolling, straightening, and welding, with limited automation and efficiency.
Innovation Solution
An automatic forming machine comprising a wire rolling system, mold system, and welding system integrated on a single machine frame, which rolls metal wires into rings, synchronously rotates the rings, and welds straight wires onto them, reducing manual intervention and increasing automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate facilities are used for rolling, straightening, and welding operations, then each operation can be performed with dedicated equipment, but the production time increases and labor costs rise due to manual transfer between machines
Solution Approach 1:
The patent combines ring rolling, straightening, and welding operations into a single integrated machine system. The ring rolling device, straightening device, and welding device are all mounted on the same machine frame and share common components such as the control system and power supply, enabling continuous automated production without manual transfer between separate facilities.
Solution Approach 2:
The patent implements automated continuous production through program control. The ring rolling device rolls metal wire into rings, which are then automatically transferred to the straightening device, and subsequently to the welding device, eliminating idle time and manual intervention between operations, thus maintaining continuous useful action throughout the production process.
2Adaptability or versatility
If manual operation is required for placing rings on welding machines, then flexibility in handling different ring sizes is maintained, but labor costs and production time increase
Solution Approach 1:
The patent implements automated self-service through program control. The system automatically positions and transfers rings from the rolling device to the welding device without manual intervention. The program control unit coordinates the movement and positioning of components, enabling the machine to serve itself in the production process while maintaining adaptability to different ring specifications.
Solution Approach 2:
The integrated machine design incorporates universal components that can handle different ring sizes and specifications. The welding device and positioning mechanisms are designed to accommodate various ring dimensions through adjustable parameters in the program control, eliminating the need for manual reconfiguration while maintaining versatility.
3Ease of manufacture
If separate facilities are used for each production step, then equipment specialization is achieved, but the overall device complexity and space requirements increase
Solution Approach 1:
The patent merges multiple specialized functions into a single integrated machine frame. The ring rolling device, straightening device, and welding device share common structural support, control systems, and power supply, reducing overall system complexity while maintaining the specialized capabilities of each function through modular design within the integrated structure.
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 automatic forming machine significantly reduces production time and labor costs while enhancing productivity by automating the rolling, straightening, and welding processes, forming plant growth supports with improved efficiency and reduced manual participation.
Implementation Method 1
a wire rolling system (10), which is for rolling a plurality of metal wires into rings
Implementation Method 2
ring welding is performed by a butt welder (electric resistance welding)
Data Source
AI summary
The present disclosure relates to an automatic forming machine for plant growth supports, comprising a ring rolling system with a ring rolling unit, a mold system with a mold unit, and a welding system, which are all disposed on a machine frame, wherein the ring rolling unit can roll a metal wire and make the metal wire be formed into a ring with an opening in the mold unit; the mold system is for carrying the ring and making two free ends of the ring with an opening aligned or alternately overlap with each other; the welding system welds can weld the opening of the ring carried by the mold unit, causing the ring to become a closed ring. The present disclosure has a high automatic degree and can reduce the production time and labor cost.