Wire Mesh Bending with Straightening for Precise High-Strength Coils
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Solution Overview
Problem
Existing wire mesh production methods using high-strength steel wires result in bulbous meshes due to the high bending stiffness, limiting the production of resilient wire meshes with precise geometry and high tensile strength.
Innovation Solution
A bending device with a straightening unit that partially straightens curved legs of the wire mesh, utilizing a guide screw and braiding knife to produce spiral blanks with controlled bending points, allowing for precise geometry and high tensile strength production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-strength steel wires are used to produce wire mesh, then the tensile strength of the wire mesh is improved, but the bending stiffness increases causing bulbous meshes with curved leg sections
Solution Approach 1:
The patent applies preliminary straightening action to the wire before bending it into the mesh structure. The straightening unit pre-treats the high-strength steel wire to reduce its curvature, enabling it to form straight leg sections in the final mesh product while maintaining the high tensile strength properties of the material.
2Strength
If the wire is bent into curved leg sections, then the wire mesh can be produced with high-strength steel, but the mesh geometry becomes bulbous and less precise
Solution Approach 1:
The straightening unit performs a preliminary action on the wire before the bending process. By pre-straightening the high-strength steel wire, the system enables precise geometric control during subsequent bending operations, producing mesh structures with straight leg sections and accurate dimensions while maintaining material strength.
Solution Approach 2:
The patent divides the wire processing into distinct functional segments: a straightening unit that pre-treats the wire, and a bending unit that forms the mesh structure. This segmentation allows each unit to optimize its specific function - the straightening unit ensures geometric precision while the bending unit maintains tensile strength, resolving the contradiction between strength and precision.
3Strength
If curved leg sections are formed in the wire mesh, then high-strength steel wires can be used, but additional compression is required to reduce mesh thickness
Solution Approach 1:
The straightening unit performs a preliminary action that eliminates the need for subsequent compression steps. By pre-straightening the wire before mesh formation, the system produces mesh structures with reduced thickness and improved geometry directly during the bending process, eliminating the need for additional plate press compression equipment and simplifying the overall production process.
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 the cost-effective, reliable, and precise production of resilient wire meshes with high tensile strength and flexibility in geometry, adapting to the properties of the used wire, while reducing curvature and enhancing load capacity.
Implementation Method 1
at least one bending unit, which has at least one guide screw and at least one braiding knife which can be rotated about an axis of rotation relative to the guide screw for producing a spiral blank with at least two curved legs
Implementation Method 2
a straightening unit which is intended to at least partially straighten the curved legs
Implementation Method 3
Due to the high bending stiffness of high-strength steel wires
Data Source
Figure 1~3
Figure 4a~4d
Figure 5a~5d
AI summary
The invention relates to a bending device (200a; 200b) for producing a wire mesh (10a; 10b), in particular a safety net, comprising multiple coils (12a, 14a; 12b) which are braided into one another and at least one coil (12a; 12b) of which is made of at least one individual wire, a wire bundle, a wire strand, a wire rope, and/or another longitudinal element (16a; 16b) with at least one wire (18a; 18b) that has a high-strength steel. The bending device comprises at least one bending unit (202a) that comprises at least one spiral guide (204a) and at least one braiding cutter (208a), which can be rotated about a rotational axis (206a) relative to the spiral guide (204a), for producing a coil blank (210a) with at least two curved limbs (212a, 214a; 212b, 214b) and with at least one bending point (216a; 216b) that connects the curved limbs by bending the longitudinal element (16a; 16b), and the bending device also comprises at least one braiding unit (218a; 218b) which is provided for braiding the coil blank (210a; 210b) into a pre-mesh (220a; 220b) of the wire mesh (10a; 10b). The bending device (200a; 200b) has a straightening device (222a) which is provided for at least partly straightening the curved limbs (212a, 214a; 212b, 214b).