This invention relates generally to the field of manufacturing cyclone fence material and more specifically to a machine for high speed weaving of chain link fence and process for making same.
Chain link fence also known as cyclone fence has been made on semi automatic machines and automatic machines for over eighty years. These machines have evolved and now in the present day in America Bergandi Machine Company, California has set the standard.
While these machines have a loyal following, there are many ways that they can be improved.
The current operation of the Bergandi machines wastes a lot of time during the cutting and indexing cycle. The Bergandi machine, when making normal 2″ diamond fence×6 ft. wide fencing, cut index cycle time is 860 ms per cycle and repeats this approximately 9,630 times in an 8-hour shift.
My invention, using the pneumatic powered high speed finger and the pneumatic powered cut and index takes 180 ms to perform the cut and index cycle. Bergandi takes 860 ms to perform the cut index cycle. The difference=680 ms. 680 ms×9,630 cycles=1.819 hours less to complete the same number of cycles resulting in approximately a 25% increase in productivity.
With my invention, this 1.819 hours saved does not reflect the additional advantage of almost zero downtime due to wire jamming.
My invention incorporates jetted compressed air through an array of nozzles, which effectively eliminates friction and the lack of torque from the wire fed through the weaving tube.
Some of the problems of the prior technology are:
The primary object of the invention is to provide a fast and easy and user friendly and safe way to do the machine setup of chain link weaving machines.
Another object of the invention is to give the operator a standard way to set the machine for all widths of fence.
Another object of the invention is to make the manufacturing operation quicker than the prior art.
A further object of the invention is one way to make the operation quicker is to use the high speed finger.
Yet another object of the invention is to raise the weaving speed threshold. That is the speed of the weaving spindle.
Another object of the invention is to enable the weaving of wider fence fabric than was possible before.
Another object of the invention is novel ability to manufacture wide (over 500 feet) fabric.
Yet another object of the invention is fabric can be woven on site to stabilize steep slopes and earth dams.
Still yet another object of the invention is wire as thin as 16 Awg can now be woven reliably.
Another object of the invention is this ability to weave very thin wire would be a major cost savings.
A further object of the invention is this novel invention would allow the weaving of high strength plastic extrusions directly from the extruder.
Yet another object of the invention is where plastic monofilament fabric would open new markets for corrosion resistant fabric.
Still yet another object of the invention is to weave chain link substantially larger than the standard 2″ diamond of the present day.
Another object of the invention is to have ability to weave 4″, 6″, 8″, 10″ and larger size diamond.
Another object of the invention is to have the ability to weave any size diamond from present day standard maximum to over 24″.
Yet another object of the invention is to meet present day ISO 9001 quality standards with ease.
Still yet another object of the invention is to vastly reduce the quantity of scrap and waste during manufacturing and setup.
Another object of the invention is to reduce the quantity of environmentally hazardous liquids during manufacture.
In accordance with a preferred embodiment of the invention, there is disclosed a machine for high speed weaving of chain link fence comprising: Pneumatic powered high speed fingers are mounted on the weaving tube and holds the loose half of the picket in a very firm grip during the start of the next incoming picket, The processor controls the timing of the extension and retracting of the high speed fingers, A pair of pneumatic slides are mounted to the machine frame with cutting blades and bending forks for the rapid cutting of the finished picket, A pneumatic cylinder mounted to the frame actuates the indexing fingers, A weaving tube mounted to the frame has two axis of adjustment. This weaving tube is equipped with coupled sets of arrayed solenoid/nozzles and proximity sensors, The array of nozzles are coupled, so the torque exerted by the effect of the jets acting on each looped extremity of the picket is exerted on the opposite sides of each loop, which gives a smooth and balanced transfer of torque to the picket, The spindle is coupled to the encoder sending precise angular information at every instant to the processor, The processor controls all functions on the machine. The processor is mounted in an enclosure. The control panel allows the operator to make all normal adjustments for operation. The control panel alerts the operator of any abnormal condition, The sensors mounted on the weaving tube sense the precise angle of the picket and this angular information is fed into the processor. The processor controls the timing and the volume of the jets media issuing from the solenoid/nozzles, Manifolds on each half of the weaving tube supply pressurized media to the solenoid/nozzles, The solenoid control system is synchronized to the speed of the spindle, and The weaving tube is precisely made from solid low friction materials.
In accordance with a preferred embodiment of the invention, there is disclosed a process for high speed weaving of chain link fence comprising the steps of: Pneumatic powered high speed fingers are mounted on the weaving tube and holds the loose half of the picket in a very firm grip during the start of the next incoming picket, The processor controls the timing of the extension and retracting of the high speed fingers, A pair of pneumatic slides are mounted to the machine frame with cutting blades and bending forks for the rapid cutting of the finished picket, A pneumatic cylinder mounted to the frame actuates the indexing fingers, A weaving tube mounted to the frame has two axis of adjustment. This weaving tube is equipped with coupled sets of arrayed solenoid/nozzles and proximity sensors, The array of nozzles are coupled, so the torque exerted by the effect of the jets acting on each looped extremity of the picket is exerted on the opposite sides of each loop, which gives a smooth and balanced transfer of torque to the picket, The spindle is coupled to the encoder sending precise angular information at every instant to the processor, The processor controls all functions on the machine. The processor is mounted in an enclosure. The control panel allows the operator to make all normal adjustments for operation. The control panel alerts the operator of any abnormal condition, The sensors mounted on the weaving tube sense the precise angle of the picket and this angular information is fed into the processor. The processor controls the timing and the volume of the jets media issuing from the solenoid/nozzles, Manifolds on each half of the weaving tube supply pressurized media to the solenoid/nozzles, The solenoid control system is synchronized to the speed of the spindle, and The weaving tube is precisely made from solid low friction materials.
Other objects and advantages will become apparent from the following descriptions, taken in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed.
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
Detailed descriptions of the preferred embodiments are provided herein. It is to be understood, however, that the present invention may be embodied in various forms. Various aspects of the invention may be inverted, or changed in reference to specific part shape and detail, part location, or part composition. Therefore, specific details disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one skilled in the art to employ the present invention in virtually any appropriately detailed system, structure or manner.
The index mechanics 111-116 are of prior art and is shown for completeness of understanding. The index cylinder 111 is mounted to the frame and transmits thrust through clevis 112. The bearings 113 hold the pivot shaft 114, and adjustable clamps 115 hold adjustable index fingers 116. Square bar 117 eliminates any twisting in the assembly.
The manifold 501, supplies array 502, which is electrically coupled to array 508 and then manifold 507 supplies pressurized media to array 508. The manifold 503, supplies array 504, which is electrically coupled to array 510 and then manifold 509 supplies pressurized media to array 510. The manifold 505, supplies array 506, which is electrically coupled to array 512 and then manifold 511 supplies pressurized media to array 512. Only one pair of coupled arrays eject pressurized media at any given time throughout the process.
Describing what is the old method of chain link manufacturing, refer to
Further describing the operation of what is old, the cutters mounted on the slides are mechanically operated by a common shaft. The shaft has cams that drive the cutter, the index mechanism, and the edging tools. The timing relationship between these functions is fixed and has been fixed to enable the thickest and most difficult size of wire specified to be woven by that particular machine. The fixed timing relationship between the function of cutting and indexing and the fact that the low speed finger 307 is mounted on the slide 305 contribute to lost time. The average time taken to cut and index is 850 milliseconds per picket woven.
The inside of the weaving tube 309 (hinged front half) and 310 (rear half) is smooth and serves only to guide the picket being woven. The weaving tube is hinged to allow the operator to remove blank pickets run into the tube during setup. Running blank pickets into the weaving tube allows the operator to adjust the over-twist needed. Over-twist is needed to counteract the successive reduction of twist and length due to friction (untwisting), so when the picket is woven into the fence, the picket is at a neutral plane and at the correct length. The operator at set up runs a picket into the tube at the set speed without engaging in any previous picket. He then uses his experience to gauge how much over-twist and over-length is required. For every slight adjustment, a blank picket is scrapped. Before each setup and after each wire jam, blank pickets need to be made resulting in much scrap metal. In a normal work day, many jams occur. Due to the fact that set up is very difficult, manufacturers tend to over produce when the machines are running smoothly, which results in increased inventory and the costs associated with the excess inventory.
The maximum weaving speed claimed today is approximately 1,190 rpm and the maximum width is 25 feet (reference Bergandi Machinery Company, California). To avoid frequent wire jams, the typical maximum operating speed is 950 rpm, and in many cases weaving speeds of 700 rpm are regularly used to ensure consistent production. Even at the lower speeds, wire jams are inevitable.
Here is what is new. The cutters are mounted to a pair of pneumatic slides that are mounted to the frame of the machine with cutting blades and bending forks for rapid cutting of the finished picket. A pneumatic cylinder mounted to the frame actuates the indexing fingers. The weaving tube is mounted to the frame with two axis of adjustment. This weaving tube is equipped with coupled sets of arrayed solenoid/nozzles and proximity sensors. The array of solenoid/nozzles are coupled,
Referring to
Because over-twist is needed to counteract the successive reduction of twist and length due to friction (untwisting), what is old has limitations of speed and maximum width that can be manufactured (950 rpm and 25 feet, respectively). This invention eliminates and counteracts the inherent friction experienced in the weaving process. The previous limitations of speed have been raised to 2,000 rpm and the previous limitation of width has yet to be determined. (It is envisioned that widths of 1,000 feet are possible.)
How this innovation works is described as follows: In the preferred method, compressed air is led into manifolds which feed an array of coupled solenoid/nozzles which blow timed pulses of compressed air onto the loops of the picket in motion in phased sequence. Only one pair of coupled arrays eject pressurized media at any given time throughout the process. These pulses of compressed air supply the exact amount of torque required to counteract the inherent friction that occurs as the picket travels through the weaving tube and the loops of the stationary picket. This arrangement allows for speeds of weaving over 2,000 rpm. This high speed would result in more than doubling present day production output. In addition, wire jams would virtually be eliminated. Because adjustments for over-twist and over-length would not be necessary, machine setting would be greatly simplified. Alternatively, in place of compressed air, any media, gaseous or liquid or steam may be used to supply torque to the picket being woven. In addition, an array of magnets may be used to pull the picket in its helical path through the weaving tube.
Referring to
Alternatively, many nozzles may be supplied by one solenoid in the array system. Alternatively, many nozzles may be triggered pneumatically. Alternatively, valve/nozzles may be pneumatically operated. Alternatively, valve/nozzles may be motorized in synchronization with the weaving speed. Alternatively, valve/nozzles may be hydraulically operated. Alternatively the pneumatic powered indexer, electric motors, hydraulic cylinders, electromechanical devices or any other means of power to achieve the end result may power cutter and high speed finger.
The frame is built on almost the same lines as what are commonly available from local manufacturers. The innovations are the items in the drawings as shown in
The weaving tube is machined from solid low friction material, and must be perfectly round in the weaving section. Arrays of precisely angled holes are drilled to coincide exactly with the helical path the picket loops take for each particular size of fabric to be woven. The arrays of solenoid/nozzles may be arranged in two pole, four pole, six pole, eight pole, or any number of poles, space permitting, depending on the diameter of the weaving tube. In the preferred embodiment of 2″ diamond fabric, three coupled arrays of solenoid/nozzles and three arrays of proximity sensors would be used. Then the proximity sensors are installed as per
The servo driven for the spindle would be more powerful than prior art to enable high acceleration and braking. The tools for performing the edges need to be changed to enable this increase in performance.
The control program is of normal common PLC processor variety as are all components such as nozzles, nozzle—solenoid combinations, pipe fittings, air cylinders and hydraulic dampers are all off-the-shelf items. Special items are the weaving blade replacing the prior art. This needs to be made from ultra-hard steel with as much stiffness as possible. This item is not adjustable as in the prior art. This is one more advantage—no tedious adding or subtracting twist to the weaving blade in the machine setting process.
The preferred method of powering the finger is pneumatic. It may be powered by any other known method to produce the same result.
The preferred position of the finger is on the third loop of the picket measured from the spindle but may be in any loop in the picket.
The finger in very wide machines may have more than one and may have as many as fifty fingers.
In the system of nozzles, the preferred media is compressed air but may include any gas or any liquid at any temperature, including steam.
In the system of nozzles, the shape of the ejected spray is to include any pattern.
In the system of nozzles, the angle of the nozzle relative to the helical path of the wire being woven may be adjusted on the fly as need be.
The nozzles may have the ability to be strictly on-off, or to have the ability to modulate the flow from zero to full on in a very fast manner.
The control system switching the nozzles and the resulting ejecta may modulate the volume of ejecta and period of ejecta as need be.
The control system receives a feedback signal from sensors mounted on the weaving tube or from a camera or from an array of laser sensors measuring the angle of the picket relative to the spindle.
The difference in the amount of angular deviation between the picket and the spindle is measured, and this difference is fed back to the control loop.
The nozzles power the picket and the picket is kept in perfect synchronization with the spindle by modulating the pressure or the time or the volume of delivery through the solenoids.
The diameter of the weaving tube may be adjustable.
The arrays of nozzles may be arranged in two pole, four pole, six pole, eight pole, or any number of poles—space permitting.
The arrays of nozzles may be replaced with electromagnets that would be mounted in a non-magnetic weaving tube.
The electromagnets would be arranged to pull the outermost loops of the steel picket and provide the required torque to the picket.
Where liquid media is used, a collection system using vacuum to recycle the liquid may be used.
The weaving tube may be ventilated in the most advantageous manner to enable the pressure in the weaving tube to be as low as possible.
The weaving tube may have a system of forced extraction of jetted media
While the invention has been described in connection with a preferred embodiment, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims.
This application is based on Provisional Application Ser. No. US60/736,257 Titled APPARATUS FOR PRODUCING CHAIN LINK FENCING
Number | Date | Country | |
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60736257 | Nov 2005 | US |