Welding Unit for Reinforcement Cage Stirrup Positioning
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Solution Overview
Problem
Existing machines for assembling reinforcement cages face challenges in welding stirrups that are close together, leading to increased cycle times and risks of interference and damage due to the geometry of the welding elements and stirrups.
Innovation Solution
A welding unit with movable electrodes that can position themselves outside and inside the stirrups, allowing for precise alignment and welding of stirrups as close as 3-5 cm apart, reducing interference and enabling efficient welding operations by moving along trajectories parallel to the stirrup plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed welding elements are used, then welding operations can be performed, but stirrups cannot be positioned at reduced distances due to interference between stirrup perimeter and welding elements
Solution Approach 1:
The welding elements are made movable rather than fixed, allowing them to dynamically adjust their position. The first welding element moves along the longitudinal axis, and the second welding element moves perpendicular to the longitudinal axis, enabling them to clear the stirrup perimeter and accommodate closely spaced stirrups without interference
Solution Approach 2:
The second welding element is positioned inside the bulk of the stirrup during insertion, navigating through the stirrup's interior space. This nested approach allows the welding element to pass through the stirrup structure without external interference, enabling precise positioning for welding operations
2Manufacturing precision
If movable welding elements are used to reduce stirrup spacing, then stirrups can be positioned closer together, but the device complexity increases
Solution Approach 1:
The welding elements are made movable rather than fixed, allowing them to dynamically adjust their position. The first welding element moves along the longitudinal axis, and the second welding element moves perpendicular to the longitudinal axis, enabling them to clear the stirrup perimeter and accommodate closely spaced stirrups without interference
Solution Approach 2:
The second welding element is positioned inside the bulk of the stirrup during insertion, navigating through the stirrup's interior space. This nested approach allows the welding element to pass through the stirrup structure without external interference, enabling precise positioning for welding operations
3Reliability
If manual welding is used for close stirrups, then interference risks are reduced, but cycle times increase
Solution Approach 1:
The welding elements are made movable rather than fixed, allowing them to dynamically adjust their position. The first welding element moves along the longitudinal axis, and the second welding element moves perpendicular to the longitudinal axis, enabling them to clear the stirrup perimeter and accommodate closely spaced stirrups without interference
Solution Approach 2:
The welding elements automatically navigate around and inside the stirrup structure through their movement capabilities, performing the welding operation without requiring manual intervention. This automation maintains high welding speeds while eliminating knock and damage risks associated with manual welding
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
Enables precise positioning and welding of stirrups in close proximity without interference, reducing cycle times and minimizing risks of damage, while allowing for flexible placement and improved quality of the cage assembly.
Implementation Method 1
The rods and each of the stirrups are normally attached by means of welding
Implementation Method 2
a welding unit including at least two welding elements, for example electrodes
Data Source
Figure 1~3
Figure 2a~2d
Figure 2e~2g
AI summary
Machine (10) and method for the production of reinforcement cages consisting of a plurality of longitudinal rods (11) connected by transverse stirrups (12) disposed at intervals along them. The machine (10) comprises a welding unit (17, 19, 117, 118, 119, 120) which has two welding elements (20, 21, 24, 27, 29) positioned, at the moment of welding, on opposite sides with respect to the rods (11) and stirrups (12) to be connected. The welding unit (17, 19, 117, 118, 119, 120) comprises a first welding element (20, 27) selectively positionable from a first inactive position in which it is outside the bulk of the relative stirrup (12) to be welded, to a second welding position in which it contacts externally a segment (12a, 12b) of the stirrup (12), and a second welding element (21, 24, 29) selectively positionable between a first inactive position in which it is outside the bulk of the relative stirrup (12), and a second welding position in which it is inside the bulk of the stirrup (12) and contacts from the inside of the latter (12) a relative rod (11) in order to keep it in contact with the segment (12a, 12b) of the stirrup (12) and prepare it for the welding operation.