Metal Wire Wiping Body Cleaning for Consistent Electrode Contact
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Solution Overview
Problem
Existing methods for cleaning metal wires used as intermediate electrodes in resistance roll seam welding machines are inefficient, inconsistent, and require frequent maintenance due to unsatisfactory cleaning by brush-covered discs, which also hinder effective cooling and controlled removal of contaminants.
Innovation Solution
A method and device utilizing a series of wiping bodies arranged along a carrier body, allowing the wire to form bow-shaped sections, combined with negative pressure and guide elements, for intensive and reliable cleaning, controlled removal of contaminants, and active cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brush-covered discs are used to clean the wire, then cleaning is performed, but the cleaning effect is unsatisfactory and inconsistent, and the discs wear quickly requiring frequent maintenance
Solution Approach 1:
The cleaning device is divided into multiple independent wiping bodies (at least three) arranged in sequence along the wire path. Each wiping body independently contacts the wire to remove contaminants, providing redundant cleaning zones that ensure consistent cleaning quality even if one wiping body wears. The wiping bodies can be individually replaced without dismantling the entire device.
Solution Approach 2:
The patent replaces the traditional brush-covered disc mechanical cleaning system with a multi-point wiping body system that uses controlled friction contact. The wiping bodies are designed to engage the wire surface at multiple discrete points rather than using rotating brushes, providing more reliable and consistent mechanical cleaning action.
2Temperature
If brush-covered discs are used for cleaning, then cleaning action is provided, but cooling of the wire is hardly possible
Solution Approach 1:
The wiping bodies serve dual functions: they clean the wire surface by removing contaminants through friction contact, and simultaneously cool the wire by conducting heat away from the wire surface during contact. This multi-functional design eliminates the need for separate cooling devices while maintaining effective cleaning action.
3Reliability
If a rotating knife disc is used to clean the wire, then cleaning is performed, but only punctual contact is achieved and thorough cleaning is not possible
Solution Approach 1:
Instead of using a single knife disc with one cutting edge, the patent employs multiple wiping bodies (at least three) arranged in sequence, each providing its own cleaning contact point. This segmentation of the cleaning function across multiple zones ensures thorough cleaning of the entire wire surface area.
4Ease of operation
If a knife disc is used for cleaning, then cleaning action is provided, but the wire can only be placed on the guide roll after the knife disc has been removed or swiveled away
Solution Approach 1:
The cleaning function is distributed across multiple fixed wiping bodies rather than one large movable knife disc. This allows the wire to be fed continuously through the device without requiring removal or movement of cleaning components, as the segmented wiping bodies are arranged to accommodate wire passage.
5Reliability
If materials stripped from the wire enter the vicinity of the device in an uncontrolled manner, then cleaning is performed, but contamination control is poor
Solution Approach 1:
The patent incorporates a suction device that actively extracts contaminants (copper dust and oxides) removed from the wire surface during the wiping process. The suction device creates negative pressure to draw contaminants away from the cleaning zone and directs them to a collection container, preventing uncontrolled dispersal into the environment.
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 thorough and consistent cleaning with minimal maintenance, effective removal of contaminants, and simultaneous cooling of the wire, ensuring high-quality electrical contact for the electrode rolls.
Implementation Method 1
the interior space is pressurized with negative pressure, as a result of which the contaminants stripped at the wiping bodies are extracted via the interior space of the carrier body
Implementation Method 2
The wire is also cooled by the sucked in air stream passing by it
Data Source
AI summary
A method for cleaning the surface of a metal wire (2) or a metal strip, in particular of a metal wire (2) or a metal strip used as an intermediate electrode of a roll seam welding machine, wherein the metal wire (2) or the metal strip is guided under tensile stress in the longitudinal direction of the wire or the strip along a plurality of wiping bodies (4) arranged at a distance one behind the other in the longitudinal direction of the wire or the strip, in such a way that the wire or the strip sections (5a-5g) each lying between two successive wiping bodies (4) together form a bow-shaped wire section. It has turned out that this enables an intensive and reliable cleaning with constant cleaning quality.