Plastic Cover Placement on Concrete Spacer Wire Ends
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Solution Overview
Problem
Existing methods for placing plastic covers on the ends of spacer wires in concrete reinforcement are not satisfactory due to issues with secure and automated placement, leading to corrosion and cover loss during handling and placement.
Innovation Solution
A system and method involving a formation press to create indentations and protrusions on wire ends, combined with a cover feeding mechanism using a rotor and plunger, ensures stable placement of plastic covers on wire ends, preventing separation and corrosion, and allowing for automated and economical processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If prefabricated plastic covers are placed on wire ends by mechanisms, then cover placement is automated, but covers fall during handling and transfer
Solution Approach 1:
The wire ends are pre-formed with protrusions and indentations during the mesh production process, before cover placement. This preliminary action creates a mechanical interlocking structure that ensures reliable cover retention during subsequent automated handling and placement operations
Solution Approach 2:
The wire ends are given localized geometric features (protrusions and indentations) only at the specific location where covers will be placed. This local modification creates a mechanical interlock structure that prevents cover detachment during automated handling while maintaining the rest of the wire properties
2Reliability
If wire ends are dipped into liquid resin or plastic, then corrosion protection is achieved, but cooling and solidification time is extended
Solution Approach 1:
The invention extracts the time-consuming cooling and solidification steps from the corrosion protection process. Instead of using liquid resin that requires cooling, the system uses pre-formed plastic covers that are mechanically attached to wire ends, eliminating the thermal processing time while maintaining corrosion protection
Solution Approach 2:
The invention replaces the thermal/chemical bonding process (liquid resin dipping and cooling) with a mechanical attachment system. The protrusions and indentations on wire ends provide mechanical interlocking with plastic covers, substituting thermal solidification with mechanical fastening
3Extent of automation
If covers are placed on wire ends during mesh production, then placement is automated, but secure attachment is difficult to achieve
Solution Approach 1:
The wire ends are pre-formed with protrusions and indentations during the mesh production process, creating a mechanical interlocking structure before cover placement. This preliminary geometric formation ensures precise and secure cover attachment when automated placement is performed
Solution Approach 2:
Localized geometric features (protrusions and indentations) are created on wire ends at the specific location for cover attachment. This local structural modification provides precise mechanical interlocking that ensures secure cover attachment during automated manufacturing
Data Source
AI summary
A product cover for the end of wire (1) of spacer meshes, and a processes and a systems for cover placement on ends of said wires (1), The wire ends of transverse wires are formed in a manner resulting in indentations and protrusions on their surfaces, so that the placement of a cover induces flow of its plastic material and creates a stable joining. Covers are serially guided inside a guide so that one of them is guided to a rotor. This rotor is then rotated to line up with the wire and a plunger for placement of the cover. Then, by the action of the plunger, this cover is pushed until fitted on the end of the wire.