Welding Wire Drum Packing with Twisted Loop Winding
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Solution Overview
Problem
Existing methods for packing welding wire in large capacity containers, such as Twist-free drums, result in inadequate packaging quality, leading to knots during unwinding, reduced packing density, and increased storage costs.
Innovation Solution
A method involving a feeding phase where the welding wire is twisted and then wound around a core with alternative upward and downward movement, allowing for controlled winding and higher packing density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the welding wire is packed using the traditional Twist-free method with free loops and 360 degree twists, then the drum can be positioned stationary on the floor or pallet, but the packaging quality is inadequate leading to knots during unwinding
Solution Approach 1:
The wire is pre-formed into loops of controlled dimensions before being placed in the drum, and the end of the wire is securely fastened to the drum bottom in advance. This preliminary preparation ensures that during unwinding, the wire maintains proper tension and geometry, preventing knots while allowing the drum to remain stationary.
Solution Approach 2:
The invention changes the geometric parameters of the wire configuration by forming precise loops with controlled dimensions and spacing, rather than using free loops. The loop dimensions and spacing are optimized to maintain wire tension and prevent tangling during unwinding, thereby improving packaging quality while keeping the drum stationary.
2Ease of manufacture
If the welding wire is packed with free loops dropped from height into the drum, then the packaging process is simple, but the wire arrangement is not neat and packing density is reduced
Solution Approach 1:
The wire is pre-formed into loops of controlled dimensions before being placed in the drum, ensuring neat arrangement and optimal space utilization. This preliminary formation allows the wire to be systematically arranged in layers, significantly improving packing density while maintaining process simplicity.
Solution Approach 2:
The wire loops are arranged in a nested pattern within the drum, with each layer of loops fitting efficiently within the drum volume. The controlled loop dimensions and spacing allow successive layers to be tightly packed, maximizing the quantity of wire that can be stored in the drum.
3Productivity
If the wire loops are dropped from a height of 30-70 mm into the drum, then the packaging is quick, but upward and radial expansion forces prevent perfect wire arrangement
Solution Approach 1:
The wire is pre-formed into loops of controlled dimensions before being placed in the drum, so that when the loops are dropped, they maintain their predetermined geometry. This preliminary formation ensures that even during quick packaging, the wire arrangement remains precise and neat, eliminating the need for complex control mechanisms during the dropping process.
4Adaptability or versatility
If the drum diameter is reduced or wire tensile strength increases, then the packaging becomes more challenging with the traditional method, but the problems of knot formation and inadequate arrangement worsen
Solution Approach 1:
The invention changes the geometric parameters of the wire configuration by forming precise loops with controlled dimensions and spacing, rather than using free loops. The loop dimensions and spacing are optimized to maintain wire tension and prevent tangling during unwinding, thereby improving packaging quality while keeping the drum stationary.
Solution Approach 2:
The wire is pre-formed into loops of controlled dimensions before being placed in the drum, and the end of the wire is securely fastened to the drum bottom in advance. This preliminary preparation ensures that during unwinding, the wire maintains proper tension and geometry, preventing knots while allowing the drum to remain stationary.
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
This method eliminates the risk of knots, achieves a higher packing density (+20% to +50% more wire per drum), and reduces storage and packaging costs by allowing for more efficient stacking and transport.
Implementation Method 1
The tube 13′ is placed in rotation around a substantially vertical axis X′, as indicated by the arrow F3, and in this way it applies a 360 degrees twist to each welding wire 25′ loop.
Data Source
AI summary
The invention has as its object a method for packing a welding wire (25) inside a container (40) which includes at least the following steps:a feeding phase of said welding wire (25) inside a tube (13) placed in rotation to produce a prefixed torsion at each wire loop (25);a winding phase of the wire (25) coming out of said tube in rotation (13) on a core (20) configured to wind said wire (25) on it, said core (20) being provided with an alternative movement in a substantially vertical direction;a wire cutting phase (25) at the end of said wire winding phase on the core to (20) and;a core pick-up phase with the wire (25) wound on it and a core introduction phase (20) with the wire (25) wound on it inside a container (40).