Wire Mesh Production with Movable Welding Heads

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Solution Overview

Problem

Existing welding machines lack flexibility in producing meshes with changeable steps and different lengths of longitudinal wires, and are inefficient in producing small quantities with openings, due to limitations in automated feeding mechanisms and fixed electrode pairs.

Innovation Solution

A system with a prefeeder carrier, feeder carrier, and welding heads equipped with controllable clutches and linear screw drives allows for independent positioning of receptacle carriers, grippers, and welding heads, enabling the production of meshes with variable spacings, diameters, and lengths, including those with openings, by programmable adjustment of wire positions and automated feeding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated feeding mechanisms with fixed electrode pairs are used, then productivity is improved, but adaptability deteriorates (cannot produce meshes with changeable steps or different lengths)

Engineering Contradiction:

Improveproduction efficiencyVSAvoidflexibility in producing meshes with changeable steps

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The welding heads are made movable along the longitudinal wires instead of being fixed, allowing dynamic adjustment of welding positions to accommodate variable mesh steps and lengths while maintaining automated production efficiency

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system divides longitudinal wires into separate groups that can be fed and welded independently, allowing different mesh configurations to be produced by selecting and welding appropriate wire groups with movable welding heads

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If manual feeding of longitudinal wires is used, then adaptability is improved (can produce various mesh configurations), but productivity deteriorates (low production efficiency)

Engineering Contradiction:

Improveflexibility in producing various meshesVSAvoidproduction efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system uses automated wire feeding mechanisms that supply longitudinal wires to movable welding heads without manual intervention, combining the adaptability of manual positioning with the efficiency of automated feeding and welding operations

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If precut wires are supplied manually from a deposition table, then adaptability is improved (can produce meshes with changeable steps), but device complexity increases (requires large number of wires at initial location and manual placement)

Engineering Contradiction:

Improveability to produce meshes with changeable stepsVSAvoidcomplexity of feeding mechanisms

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The welding heads and wire feeding positions are made dynamically adjustable along the production line, allowing the system to adapt to different mesh configurations without requiring complex static arrangements of wire storage and manual placement mechanisms

Inventive Principle:

Principle #15Dynamics

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

The system achieves flexible and efficient production of meshes with changeable steps and different lengths, including those with openings, by allowing precise control over wire positioning and automated feeding, enhancing productivity and versatility.

Implementation Method 1

with these carriers, in turn being located upon a prefeeder carrier. A feeder carrier with grippers transports them (the rods/wires, that is) towards the welding heads

Methodology Applied

Scientific EffectScrew mechanism: Screw

Data Source

PatentUS10421146B2Methods and systems for production of mesh from wires or rods, with changeable steps for longitudinal and transverse rods

Publication Date: 2019.09.24 ANAGNOSTOPOULOS ANTONIOS

AI summary

Systems and methods for producing mesh from wires or rods with programmed changeable steps for the longitudinal and transverse wires. The longitudinal wires (1) and the transverse wires (12) may be fed from coils or be precut. The longitudinal wires are fed in receptacles (2) on carriers (3) with the carriers being found on prefeeder carrier (4), a feeder carrier (6) with grippers (7) transports them towards the welding heads (10) and the produced mesh (20) is received by a mesh carrier (14). The carriers (3) with the receptacles (2) for the longitudinal wires on the prefeeder carrier (4), the grippers for the longitudinal wires (7) at the feeder carrier (6) and the welding heads (10) are displaced in the direction of the transverse wire without restrictions, generally in an unrestricted fashion, so as to correspond to the longitudinal wires being subjected to welding. The transverse wires are fed towards the welding heads to be welded with the longitudinal wires. The machine produces meshes with openings, grouping the longitudinal wires in groups and feeding the groups of longitudinal wires towards the welding heads, adjusting the position of the related mechanisms to the position of the longitudinal wires.