Wire Mesh Welding Layout for Variable Pitch and Free-Form Mats
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Solution Overview
Problem
Existing automated wire mesh welding systems are limited by fixed product pitches, restricting the variation of mesh width and length, and cannot produce customized or free-form mesh products efficiently.
Innovation Solution
A method and system that allows for fully flexible design of wire mesh mats by moving longitudinal wires in both X and Y directions, using detachable clamps and adjustable welding units, enabling variable grid patterns and pitches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If automated wire mesh welding systems use fixed receiving devices for longitudinal wires, then the system structure is simple and stable, but the product pitch cannot be varied and customization is limited
Solution Approach 1:
The receiving devices for longitudinal wires are made movable in the Y-direction instead of being fixed, allowing dynamic adjustment of the distance between longitudinal wires. This enables variable product pitch and customized mesh patterns while maintaining automated welding operations.
Solution Approach 2:
The welding portal is designed to accommodate multiple welding units that can be positioned at different locations, allowing the same system to produce various mesh configurations (different pitches, patterns, and designs) without requiring separate dedicated equipment for each product type.
2Adaptability or versatility
If the distance between longitudinal wires is fixed by immovable guides, then the manufacturing process is simple and stable, but free product shapes and customized designs cannot be realized
Solution Approach 1:
The longitudinal wire guide elements are made adjustable in the Y-direction, transforming the static manufacturing process into a dynamic one where wire positions can be changed to create free-form product shapes and customized designs.
Solution Approach 2:
The system allows continuous variation of geometric parameters (distance between longitudinal wires, mesh pitch, pattern configuration) through programmable control of movable components, enabling diverse product shapes and designs from a single manufacturing setup.
3Productivity
If receiving devices are positioned to produce fixed mesh width, then production is efficient and automated, but variation of mesh width and length within or between mats is restricted
Solution Approach 1:
The receiving devices for longitudinal wires are equipped with programmable movement capabilities in the Y-direction, allowing the system to automatically adjust mesh dimensions during production while maintaining high-speed automated welding operations.
Solution Approach 2:
The system uses programmable control to dynamically change geometric parameters (mesh width, length, pitch) during production, enabling varied product specifications without sacrificing automated production efficiency.
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 highly customizable wire mesh mats with variable pitches, sizes, and shapes without requiring system changes, allowing for efficient and flexible manufacturing of customized products.
Implementation Method 1
welding at least one first longitudinal wire to a first cross wire
Data Source
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AI summary
The invention relates to 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.