Wire Mesh Separation Gaps for Multi-Width Panel Production
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Solution Overview
Problem
The existing methods for manufacturing smaller width wire mesh rolls or panels are inefficient as they require the same production time, man-hours, and energy as producing multiple rolls or panels simultaneously, leading to underutilization of manufacturing capacity and increased waste in post-production processing.
Innovation Solution
A wire processing system that receives line wires and cross wires, welds them, and includes an advancing system for forming wire mesh, with a selective cutting mechanism to create gaps in the mesh, allowing for the simultaneous production and easy separation of multiple smaller width rolls or panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If smaller width wire mesh rolls or panels are manufactured individually using a large width welding machine, then the manufacturing flexibility is improved, but the productivity deteriorates due to underutilization of manufacturing capacity
Solution Approach 1:
The patent divides a large width wire mesh panel into multiple smaller width panels by introducing cuts through the mesh structure. This segmentation allows the welding machine to produce a large panel that is then divided into smaller usable panels, thereby utilizing the full manufacturing capacity of the large width welding machine while still providing smaller width products.
2Adaptability or versatility
If smaller width wire mesh rolls or panels are manufactured individually, then the product variety is improved, but the loss of time deteriorates due to repeated processing steps
Solution Approach 1:
The patent performs the welding of a large width panel first, and then subsequently introduces cuts to divide it into smaller panels. This preliminary action of welding the entire panel at once, followed by segmentation, eliminates the need to repeatedly set up and operate the welding machine for each smaller panel, thereby reducing production time while maintaining product variety.
3Adaptability or versatility
If smaller width wire mesh rolls or panels are manufactured individually, then the customization capability is improved, but the loss of substance deteriorates due to increased waste in post production processing
Solution Approach 1:
The patent introduces cuts through the wire mesh panel to divide it into multiple smaller panels. By producing a large panel first and then segmenting it, the system maximizes material utilization and minimizes waste compared to producing each smaller panel individually, as the cuts are made after the efficient large-scale welding process is complete.
4Ease of operation
If smaller width wire mesh rolls or panels are manufactured individually, then the operational flexibility is improved, but the device complexity deteriorates due to multiple processing steps
Solution Approach 1:
The patent performs the welding operation on a large width panel first, establishing the complete mesh structure in a single efficient process. The cutting operation is then introduced as a subsequent, simpler step to divide the panel into smaller sections. This sequencing reduces overall device complexity by avoiding the need for multiple complex welding setups while maintaining operational flexibility.
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 system enables efficient and economical manufacturing of multiple smaller width wire mesh rolls or panels by reducing production time and waste, as the cutting process allows for the separation of distinct panels with minimal additional processing steps.
Implementation Method 1
a welding station for receiving the cross wire and the plurality of line wires, said welding station providing that the cross wire is welded to the plurality of line wires
Data Source
AI summary
A wire-mesh is disclosed that is formed of wires in a warp direction bonded to wires in a fill direction that is mutually orthogonal with respect to the warp direction, wherein the wire-mesh includes at least one gap that extends in any of the warp direction or the fill direction, the gap being formed of mutually-contiguous breaks in any of the warp direction wires and the fill direction wires, the gap facilitating separation of the wire-mesh.