Integrated Station for Wire Insertion and Welding in Sandwich Panels
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Solution Overview
Problem
Existing machines for producing sandwich building panels with metal nettings and expanded plastic material require two stations for inserting, cutting, and welding crosspieces, which limits penetration depth and increases production complexity, while also being inefficient in material usage and productivity.
Innovation Solution
A device and method that integrate preheating, cutting, and welding functions into a single station on the conveyor line, using pivoting forks with electrodes for precise insertion, cutting, and welding of metal wires into expanded plastic material between metal grids, allowing deeper penetration and reduced material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If two stations are used for inserting, cutting, and welding crosspieces, then welding operations can be completed, but penetration depth is limited and device complexity increases
Solution Approach 1:
The patent combines insertion, cutting, and welding operations into a single integrated station. The device includes a insertion device with a cutting tool and a welding device that operate simultaneously at the same location, eliminating the need for separate stations and enabling deeper crosspiece penetration without increasing device complexity
Solution Approach 2:
The patent implements continuous simultaneous operations where insertion, cutting, and welding occur in one continuous action at a single station. The crosspiece is inserted through the plastic layer, cut to the exact depth required, and welded to the reinforcement element all in one continuous process, maximizing penetration depth while maintaining operational efficiency
2Productivity
If two stations are used for inserting, cutting, and welding crosspieces, then welding operations can be completed, but productivity decreases
Solution Approach 1:
The patent merges multiple operations (insertion, cutting, welding) into a single station that performs all functions simultaneously. This eliminates the need for the product to be transported between multiple stations, reducing cycle time and increasing productivity while maintaining comprehensive functionality
Solution Approach 2:
The single station is designed as a multi-functional device that can perform insertion, cutting, and welding operations. The insertion device includes a cutting tool, and the welding device can weld at different positions, making the single station universally capable of completing all required operations that previously required multiple specialized stations
3Manufacturing precision
If metal wires are inserted through expanded plastic material, then crosspieces are formed, but material damage occurs at entry and exit surfaces
Solution Approach 1:
The patent applies preheating to the metal wire crosspieces before insertion. The preheating softens the plastic material at the entry and exit points, allowing the heated wire to pass through with minimal damage to the plastic surfaces. This preliminary thermal preparation ensures clean entry and exit holes while maintaining the structural integrity of the plastic layer
Solution Approach 2:
The patent changes the temperature parameter of the metal wire by heating it before insertion. This temperature change allows the wire to melt or soften the plastic material it passes through, creating smooth entry and exit holes without damaging the surrounding plastic structure. The parameter change from cold to hot wire enables precise control over the insertion process and surface integrity
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 efficient and versatile production of sandwich panels with improved penetration and reduced material damage, maintaining existing production line efficiency and versatility, while allowing for more complex panel structures and reduced production costs.
Implementation Method 1
heating the ends of the crosspieces to be introduced, carried out by engaging the ends of the wires to be introduced through a pair of electrodes alternating in opposite translation
Implementation Method 2
sectioning the crosspieces introduced through the plastic material, to define the required sections, while welding them to the grid
Implementation Method 3
welding them to the grids on the two sides
Data Source
Figure 1
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AI summary
Device and method for inserting, sectioning and fixing wire-like metal elements (6) into plastic materials enclosed between twinned metal nettings, particularly for introducing, defining and welding crosspieces in automatic "sewing" machines for producing sandwich prefabricated panels made of metal grids and expanded plastic material. The welding operation takes place by at least one pair of electrodes (9, 10) wherein a cutting insert (15) is embedded in one electrode (9) such the said electrodes serve also for sectioning the metal wire (6)and welding its apex with the weft wire (16) in a single station for the advancement of the product.