Wire Mesh Welding Busbar Layout for Uniform, Low-Energy Welds
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Solution Overview
Problem
Existing welding devices for wire meshes require high energy, are costly, require frequent maintenance, and have long adjustment times, while also producing welds of varying quality.
Innovation Solution
The welding device features two busbars connected to transformers via current paths, forming a sandwich with an insulator, with lines leading to electrodes on both sides of the plane, and includes bridges for energy input and elongated plates between parallel wires, allowing for efficient energy distribution and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional welding devices with multiple separate current paths are used, then welding function is provided, but energy consumption is high and device complexity is increased
Solution Approach 1:
The patent combines multiple separate current paths into a single unified current path that serves all welding electrodes. Instead of having independent transformers and current paths for each electrode, the invention uses one transformer with a primary winding and multiple secondary windings that share a common magnetic core, thereby reducing the number of components and lowering energy consumption while maintaining welding functionality across multiple electrodes.
2Productivity
If traditional welding devices are used, then welding is performed, but adjustment times are long and productivity is reduced
Solution Approach 1:
The patent implements adjustable secondary winding ratios in the transformer that can be dynamically changed during operation. This allows the welding parameters to be adjusted quickly without requiring physical reconfiguration of the entire welding system, thereby reducing adjustment times and improving productivity while maintaining versatile welding capabilities.
3Reliability
If traditional welding devices are used, then welding is performed, but weld quality varies and reliability is reduced
Solution Approach 1:
The patent designs the transformer secondary windings to provide equal voltage output to all welding electrodes through balanced winding ratios. This equipotential design ensures that each electrode receives consistent electrical energy, resulting in uniform weld quality across all welding points and improving reliability by eliminating variations caused by unequal energy distribution.
4Adaptability or versatility
If more transformers and current paths are added, then welding coverage is improved, but device complexity and cost increase
Solution Approach 1:
The patent creates a universal transformer design where a single transformer with multiple secondary windings can serve multiple welding electrodes simultaneously. This multi-functional approach allows the system to provide welding coverage for multiple electrodes while maintaining a compact, integrated structure that avoids the complexity of having separate transformers for each electrode, thereby improving versatility without proportionally increasing device complexity.
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 configuration reduces energy consumption, minimizes adjustment times, enhances weld quality, and reduces material usage, while maintaining adaptability to different wire mesh configurations and minimizing magnetization.
Implementation Method 1
multiple electrodes (7), which are connected to transformers (3) via current paths (4)
Implementation Method 2
introduction of electrical energy into welding machines for the production of industrial mesh and fence mesh mats by means of medium-frequency welding
Data Source
AI summary
A welding device for wire meshes which extend in a plane with a predefined width and have meshes, wherein said welding device comprises multiple electrodes which are connected to transformers via current paths.