Welding Wire Pressing Member Projection Design
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Solution Overview
Problem
Welding wire stored in pail packs often becomes tangled or kinked during decoiling, leading to decoiling failures, which result in inefficiencies and waste, as the wire can slip off the coil and bind around the inner shell, causing irregular behavior and kinking.
Innovation Solution
A pressing member with a flat body and a projection that extends downward from the inner peripheral edge, providing a pressing margin and a curved surface to guide the wire along a constant path, preventing tangling and kinking by applying an appropriate pressing force to maintain the decoiling path and prevent irregular shifting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gap is provided between the coil and the inner shell to prevent wire binding, then decoiling failure due to wire binding is prevented, but the wire may slip off into the gap and become tangled or kinked
Solution Approach 1:
The pressing member features a pressing margin with a specific width (5-135mm) that creates a localized pressing zone. This local quality differentiation allows the pressing member to apply controlled pressure at the inner peripheral edge of the coil without requiring a large gap, thereby preventing wire slip-off while maintaining adequate space to prevent binding.
Solution Approach 2:
The invention optimizes the gap width between the pressing member and inner shell within a specific range (10-100mm). By changing this parameter to an optimal value, the system prevents both wire binding (which occurs with insufficient gap) and wire slip-off (which occurs with excessive gap), resolving the contradiction between these two harmful effects.
2Stability of the object's composition
If the pressing member weight is increased to prevent wire irregular behavior, then decoiling stability improves, but the wire may become distorted under excessive weight
Solution Approach 1:
The pressing margin creates a localized pressing zone that provides stability where needed (at the inner peripheral edge) without applying excessive force to the entire wire coil. This local quality approach maintains decoiling stability while preserving wire linearity by concentrating the pressing action only where slip-off occurs.
Solution Approach 2:
The invention optimizes the pressing member weight and pressing margin width within specific ranges to achieve the right balance between stability and wire integrity. By changing these parameters to optimal values, the system provides sufficient pressing force for stability while avoiding distortion of the wire shape.
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 solution effectively prevents wire tangling and kinking, reducing decoiling failures and ensuring a smooth, efficient unwinding process by maintaining the decoiling path and applying a controlled pressing force, thus minimizing wire loss and maintaining wire linearity.
Implementation Method 1
an annular pressing plate is placed on the top of the coil of the welding wire. That is, the jumping of the wire is prevented under the weight of the pressing plate applied to the coil of the wire from above
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A welding-wire-storing pail pack is provided in which a pressing member (10) includes an annular body (10a) positioned on a coil (30) of welding wire, a pressing margin extending from a position on an underside of the body (10a) at an inner peripheral edge of the coil (30) toward an axis of the coil (30), and a projection (12) provided on an inner peripheral edge of the pressing margin in such a manner as to project downward. The body (10a) has an inner diameter of 200 to 470 mm. A gap of 10 mm at the minimum is provided between an inner shell and the body (10a). The pressing member (10) weighs 600 to 2000 g. Thus, the wire is prevented from being tangled and/or kinked when being pulled out, and the occurrence of decoiling failure is prevented.