Wire Mesh Welding Layout for Variable Grid Reinforcement Mats
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Solution Overview
Problem
Current automated wire mesh welding systems are limited in producing reinforcement mesh products with varying mesh widths and lengths, restricting product customization and optimization for individualized and design-optimized end products.
Innovation Solution
A method and system that allows for fully flexible design of wire mesh mats by using a clocked feed device for longitudinal wires and a welding portal to weld intersecting wires, enabling adjustable grid patterns and variable wire lengths and diameters, with a pull-out beam for efficient mat production and handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated wire mesh welding systems are used with fixed grid configurations, then production efficiency is improved, but product flexibility and customization capability deteriorate
Solution Approach 1:
The patent implements dynamic adjustability in the wire feeding system, allowing the grid configuration to be changed during production. The longitudinal and transverse wire feeders can be independently controlled to create variable mesh patterns, enabling the system to adapt to different product requirements while maintaining automated production efficiency.
Solution Approach 2:
The system enables parameter changes in mesh width, mesh length, and wire spacing through programmable control. The wire feeders can be adjusted to deliver wires at varying intervals and positions, allowing production of customized mesh mats without reconfiguring the entire welding system physically.
2Manufacturing precision
If fixed mesh width and length are produced on automated systems, then manufacturing precision is improved, but product variety and individualization capability deteriorate
Solution Approach 1:
The welding system incorporates dynamic positioning capabilities where the welding head and wire feeders can be programmatically controlled to create precise yet variable mesh configurations. This allows the system to maintain manufacturing precision for each specific product specification while enabling production of multiple product varieties through software control rather than physical reconfiguration.
3Device complexity
If traditional wire mesh production systems are used, then system simplicity is maintained, but capability to produce free product forms and special products deteriorates
Solution Approach 1:
The patent describes a universal wire mesh welding system that can produce multiple product types and configurations using the same basic equipment. The system incorporates programmable control and adjustable wire feeders that enable production of standard mesh mats as well as custom shapes and patterns, eliminating the need for dedicated equipment for different product types.
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 production of wire mesh mats with customizable mesh patterns, sizes, and wire configurations, including overhangs and recesses, allowing for individualized or series production without system modifications, achieving flexible and efficient manufacturing.
Implementation Method 1
welding the wires at their intersection points
Data Source
AI summary
A method for producing a wire mesh mat that consists of intersecting longitudinal and transverse wires and to a mesh welding facility for welding a wire mesh mat from intersecting longitudinal and transverse wires, comprising a clocked supply device for a sheet of longitudinal wires in an X direction, a feed device for transverse wires that lie perpendicular to the longitudinal wires and to a welding portal for welding the wires at their intersections.