Metal Wire Cutting Machine Synchronized Marking Unit
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Solution Overview
Problem
Existing metal wire cutting machines for TIG welding rods have limited productivity due to the need to stop the wire for marking, produce noise from hydraulic systems, and result in anti-aesthetic signs on the pieces.
Innovation Solution
A metal wire cutting machine with an advancement unit, a cutting unit using a cutting blade driven by electric motors, and a marking unit with dies that move in synchronization with the wire to perform 'on-the-fly' marking and cutting, reducing noise and preventing unwanted signs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the wire is stopped for marking, then marking precision is improved, but productivity deteriorates
Solution Approach 1:
The marking system transitions from a static stopping mechanism to a dynamic moving marking mechanism. The marking unit moves synchronously with the wire advancement, allowing marking to be performed during continuous wire motion rather than requiring the wire to stop, thus maintaining both precision and productivity
Solution Approach 2:
The wire advancement continues uninterrupted during the marking process. The marking operation is integrated into the continuous wire feeding process, eliminating idle stopping time and maintaining continuous productive action throughout the marking cycle
2Ease of operation
If hydraulic cylinders are used for marking, then marking function is achieved, but noise increases
Solution Approach 1:
The hydraulic cylinder system is replaced with an electric motor-driven mechanism. The electric motor synchronously drives the marking unit to move with the wire advancement, eliminating the noisy hydraulic system while achieving the same marking function through electrical mechanical drive
Solution Approach 2:
The patent replaces the hydraulic power transmission system with an electric motor direct drive system, eliminating hydraulic fluid pressure fluctuations and associated noise while maintaining the marking capability through electrical actuation
3Manufacturing precision
If the wire stops against the reference surface, then cutting precision is improved, but anti-aesthetic signs are produced
Solution Approach 1:
The straightening rollers transition from a static contact system to a dynamic synchronous rotation system. The rollers rotate at the same speed as the wire advancement, eliminating relative sliding motion that causes aesthetic signs while maintaining the wire straightening and positioning function for precise cutting
Solution Approach 2:
The sliding friction-based straightening mechanism is replaced with a rolling friction mechanism. The straightening rollers rotate synchronously with wire movement, substituting sliding contact with rolling contact to eliminate surface marks while maintaining mechanical support and straightening function
Data Source
Figure 1
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AI summary
Machine (1) for cutting and marking a metal wire (2) comprising: an advancement unit (3) for moving the metal wire (2) at a predefined advancement speed according to an advancement direction (X) parallel to the axis of the metal wire (2); a marking unit (4) for engraving signs on the metal wire (2), comprising a die (6, 6') associated to a driving unit (7) configured to define, for the die (6, 6'), a movement trajectory in contact with the metal wire (2); a cutting unit (5) for cutting the metal wire (2) into pieces, comprising a cutting blade (8, 8') associated to driving means (9). The driving unit (7) is configured so that the movement trajectory has, in each point, a motion component directed according to the advancement direction (X).