Wire Billet Coil Butt-Welding with Automatic Flipping and Loading
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Solution Overview
Problem
Conventional wire billet butt-welding methods are labor-intensive, pose safety hazards, and have low productivity due to manual handling and flipping of heavy coils, which complicates the process and increases the risk of accidents.
Innovation Solution
A wire billet butt-welding apparatus featuring a rotary plate and a butt-welding stock receiver that enables automatic loading, flipping, and discharging, along with a stock receiving rod and pushing mechanism for semi-automatic operation, reducing manual labor and enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual flipping operation is used to re-order wire billet coils, then the process can be completed with simple equipment, but the labor intensity is high and safety hazards increase
Solution Approach 1:
The wire billet coil performs self-flipping through controlled unwinding and rewinding. The coil is fed through a guide roller and wrapped around a reel, causing it to flip automatically without manual intervention. This eliminates the need for workers to manually handle heavy coils, reducing labor intensity and safety hazards while maintaining equipment simplicity.
Solution Approach 2:
The system transitions from static manual flipping to dynamic automated flipping. The wire billet coil is continuously fed and unwound at controlled speeds, creating a dynamic process where the coil flips automatically during the unwinding and rewinding cycles. This dynamic approach replaces static manual operations with automated motion control.
2Device complexity
If manual flipping operation is used to re-order wire billet coils, then the equipment can be simple, but productivity is reduced
Solution Approach 1:
The wire billet coil flipping process is integrated into the continuous feeding operation. As the coil is continuously fed through the guide roller and wrapped around the reel, the flipping action occurs automatically during the same operational cycle. This eliminates separate manual flipping steps, ensuring continuous useful action and improving productivity without significantly increasing equipment complexity.
3Device complexity
If manual handling of heavy wire billet coils is performed, then equipment can be simple, but safety hazards increase
Solution Approach 1:
The wire billet coil performs self-flipping through controlled unwinding and rewinding. The coil is fed through a guide roller and wrapped around a reel, causing it to flip automatically without manual intervention. This eliminates the need for workers to manually handle heavy coils, reducing labor intensity and safety hazards while maintaining equipment simplicity.
4Ease of operation
If automatic loading and flipping mechanisms are implemented, then labor intensity is reduced, but device complexity increases
Solution Approach 1:
The wire billet coil performs self-flipping through controlled unwinding and rewinding. The coil is fed through a guide roller and wrapped around a reel, causing it to flip automatically without manual intervention. This eliminates the need for workers to manually handle heavy coils, reducing labor intensity and safety hazards while maintaining equipment simplicity.
Solution Approach 2:
The feeding mechanism serves multiple functions: it feeds the wire billet coil, guides it through the welding position, and simultaneously performs the flipping operation by wrapping the coil around the reel. This multi-functionality reduces the need for separate dedicated flipping equipment, thereby limiting the increase in overall device complexity while achieving automatic operation.
5Productivity
If automatic loading and flipping mechanisms are implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The wire billet coil flipping process is integrated into the continuous feeding operation. As the coil is continuously fed through the guide roller and wrapped around the reel, the flipping action occurs automatically during the same operational cycle. This eliminates separate manual flipping steps, ensuring continuous useful action and improving productivity without significantly increasing equipment complexity.
Solution Approach 2:
The feeding mechanism serves multiple functions: it feeds the wire billet coil, guides it through the welding position, and simultaneously performs the flipping operation by wrapping the coil around the reel. This multi-functionality reduces the need for separate dedicated flipping equipment, thereby limiting the increase in overall device complexity while achieving automatic operation.
Data Source
AI summary
To solve the problems of conventional wire billet butt-welding such as high labor intensity, potential safety hazards, and low production efficiency, the disclosure provides a wire billet butt-welding apparatus and a wire billet butt-welding method. The wire billet butt-welding method comprises: S1: preparing a stock, S2: rotating a butt-welding stock receiver to a stock receiving position, and feeding a first coil of wire billet to a stock receiving rod of the butt-welding stock receiver; S3: welding the first coil of wire billet and the second coil of wire billet on a rotary plate at the butt-welding position end-to-head; S4: rotating the butt-welding stock receiver and the second coil of wire billet to the stock receiving position; S5: rotating the stock receiving rod to rotate to tighten the wire billet between the first coil of wire billet and the second coil of wire billet; and S6: repeating steps S3 to S5 to complete butt-welding operations on the 3rd to nth coils of wire billet sequentially. The solution implements semi-automated butt-welding operation; with provision of the rotary plate and the butt-welding stock receiver, enables automatic loading, automatic flipping, and automatic discharging, which reduces the manual workload, lowers the safety hazards, and improves the production efficiency.