Polygonal Wire Coil Packing to Prevent Settling and Tangling
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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 container space and operational issues during welding.
Innovation Solution
A wire coiling apparatus with a rotatable laying head and X-Y table that forms wire loops in a polygonal array within a storage container, ensuring the loops match the container's interior shape, minimizing gaps and stabilizing the wire coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If cylindrical wire coils are arranged in a container with octagonal liner, then the wire can be packaged in bulk, but gaps form between the cylindrical coils and octagonal liner walls causing wire settling and tangling
Solution Approach 1:
The patent transforms the wire coil arrangement from cylindrical to polygonal cross-section, where the wire loops are formed with polygonal geometry matching the octagonal liner. This curvature adaptation eliminates gaps between the wire coils and liner walls, preventing wire settling and tangling during shipment while maintaining bulk packaging capacity.
Solution Approach 2:
The patent introduces asymmetry by changing the wire coil cross-section from symmetric cylindrical shape to asymmetric polygonal shape that conforms to the octagonal liner geometry. This asymmetric adaptation allows the wire loops to fit tightly against the non-circular liner walls, eliminating the gap problem caused by cylindrical coils in octagonal containers.
2Ease of manufacture
If cylindrical wire loops are formed by conventional coiling methods, then the coiling process is simple, but the loops do not fit closely to octagonal container walls requiring taller containers
Solution Approach 1:
The wire laying head is modified to form polygonal cross-section wire loops instead of cylindrical loops. The laying head geometry is adapted to extrude wire in polygonal configuration, allowing the loops to conform to the octagonal liner walls and maximize container space utilization, thereby reducing required container height.
Solution Approach 2:
The patent changes the geometric parameters of the wire loop cross-section from circular to polygonal shape. This parameter modification allows the wire loops to match the octagonal container geometry, improving packing density and reducing container height requirements while maintaining manufacturing feasibility through adapted laying head design.
3Stability of the object's composition
If polygonal wire loops are formed to match octagonal liner walls, then wire settling is prevented, but the coiling apparatus complexity increases with X-Y table movement
Solution Approach 1:
The X-Y table serves multiple functions: it positions the wire laying head precisely during coiling, supports the container during filling, and enables the formation of polygonal loops through coordinated movement. This multi-functionality justifies the added complexity by providing both positioning and support capabilities in a single device.
Solution Approach 2:
The X-Y table acts as an intermediary device that mediates between the wire laying head and the container. It provides the necessary movement and positioning capability to form polygonal loops while supporting the container, thereby enabling the complex polygonal coiling process through a dedicated intermediary mechanism.
Data Source
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AI summary
A container (C) includes an outer box (10), and a polygonal liner (22) located within the outer box (10). The polygonal liner (22) has a plurality of vertical walls. A continuous length of wire (34) is located within the polygonal liner (22) 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 (22). The invention further provides a wire coiling apparatus (32) and a method of packaging a wire coil.