Longitudinal Wire Rotation for Planar High-Speed Mesh Welding
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Solution Overview
Problem
Existing mesh production systems face inefficiencies in wire straightening, leading to residual curvature in wires and rods, which results in poor mesh planarity and low productivity due to the need for slower rotor straighteners and inflexibility in changing wire diameters and lengths.
Innovation Solution
A system that includes a wire straightener, cutter, rotator unit, and carrier system to controllably rotate cut longitudinal wires around their axes to specified angles before storage and welding, allowing for higher speed production and flexibility in wire diameter changes, while using rollers for straightening and advancement to enhance productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rotor straighteners are used to achieve perfect straightening quality, then manufacturing precision is improved, but productivity deteriorates due to relatively low speed
Solution Approach 1:
The patent changes the operational parameters of the straightener from slow rotor-based straightening to high-speed roller-based straightening. By adjusting the roller speed, pressure, and configuration, the system achieves both high straightening quality and high production speed, eliminating the need for slow rotor straighteners while maintaining manufacturing precision.
Solution Approach 2:
The patent replaces the rotor straightening mechanism with a roller-based mechanical system. This substitution allows for higher operational speeds while maintaining straightening effectiveness, thereby improving productivity without sacrificing manufacturing precision.
2Productivity
If roller straighteners are used to achieve high speed production, then productivity is improved, but manufacturing precision deteriorates due to residual curvature and bow-effect
Solution Approach 1:
The patent applies preliminary straightening actions through rollers before the wire enters the welding position. By pre-positioning the wire in a straight configuration at high speed, the system eliminates residual curvature and bow-effect while maintaining high productivity. The rollers are configured to apply corrective forces in advance, ensuring straightness is achieved before welding occurs.
Solution Approach 2:
The patent optimizes roller parameters including speed, pressure, spacing, and angle to achieve both high feeding speed and excellent wire straightness. By carefully adjusting these parameters, the system produces wires with minimal residual curvature while maintaining high production rates.
3Adaptability or versatility
If multiple reels and spools are used to handle different wire diameters, then adaptability is improved, but area occupied increases significantly
Solution Approach 1:
The patent employs universal reels and spools that can handle multiple wire diameters through adjustable configurations. The straightener and feeding mechanisms are designed with adjustable parameters that accommodate different wire sizes, allowing a single set of equipment to perform multiple functions. This eliminates the need for multiple dedicated reels and spools, significantly reducing the area occupied while maintaining adaptability to different wire diameters.
4Manufacturing precision
If rotor straighteners are used to achieve perfect straightening, then manufacturing precision is improved, but loss of time increases due to low processing speed
Solution Approach 1:
The patent replaces the time-consuming rotor straightening mechanism with a high-speed roller-based system. The rollers can operate at much higher speeds while maintaining straightening effectiveness, thereby reducing processing time significantly without compromising manufacturing precision.
Solution Approach 2:
The patent implements continuous straightening action through rollers that operate throughout the wire feeding process. This continuous action at high speed eliminates the time loss associated with slower rotor straightening, maintaining perfect straightness while minimizing processing time.
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3C
AI summary
The present invention relates to machines, systems and processes for feeding longitudinal wires (2) for mesh (6) production. Welding of longitudinal wires (2) with transverse wires (4) at welding unit (57) produces mesh (6). Longitudinal wires (2) are controllably rotated around their longitudinal axes to selected angles, and restrained until their welding with transverse wires (4), thus negating effects of residual curvature from roller straightener (36) and resulting in mesh (6) produced planar with distortion stresses effectively neutralized. A wire collector (79) releases a first longitudinal wire (2) for guided travel laterally to a receptacle (45). A rotator unit (71) simultaneously controllably rotates this wire, while the collector (79) simultaneously receives the length of the next longitudinal wire. Particular rotator units (71) facilitate such operation. In some versions an advancement roller assembly (120) proximate to the welding unit (57) may advance longitudinal wires (2) through the welding unit, freeing a longitudinal wires carrier (31) to return to the longitudinal storage (32) and to receive a next set of longitudinal wires.