Patent Application
20240058858
The invention concerns a steel wire netting, a production device and a production method.
In the Polish patent document having the patent number PL 235814 B1 a hexagonal netting is described which is made of a high-tensile steel with a tensile strength between 1,500 N/mm2 and 1,900 N/mm2. However, the hexagonal netting described here has a special, in particular elongate, mesh shape, in which a ratio of mesh width and mesh height is compellingly always smaller than 0.75. According to the aforementioned patent document, this mesh geometry substantially differs from customary mesh geometries of hexagonal nettings made of non-high-tensile steel wires, which are typically 60 mm×80 mm (ratio 0.75), 80 mm×100 mm (ratio 0.8) or 100 mm×120 mm (ratio 0.83). These mesh dimensions are, however, clearly defined in a European standard for “steel wire nettings having hexagonal meshes for civil engineering purposes” (EN 10223-3:2013). Meshes having mesh width/mesh height ratios of less than 0.75, i. e. the mesh width/mesh height ratios described in patent document PL 235814 B1, thus do not comply with the requirements of the European standard. The hexagonal mesh depicted in patent document PL 235814 B1 even has a mesh width/mesh height ratio that is merely 0.62. Only if the mesh width/mesh height ratio is 0.75 or more, the hexagonal nettings are also standard-compliant and are thus usable for civil engineering purposes in a regular fashion. In contrast thereto, in the ninth paragraph of patent document PL 235814 B1 it was clearly described that, in the opinion of the patent owner, it was currently not possible to make standard-size hexagonal nettings from high-tensile steel wires, and therefore a different (smaller) mesh width/mesh height ratio was necessarily required if high-tensile steel is used. Actually, on the market the demand for high-tensile hexagonal nettings was and is of such dimensions that the patent owner of patent document PL 235814 B1 offers and distributes the non-standard-compliant hexagonal nettings described in said patent document in spite of that. The market has for a long time shown a huge need for high-tensile hexagonal nettings which at the same time fulfill the requirements according to the standard EN 10223-3:2013 with regard to mesh shape and mesh dimensions, in particular with regard to the mesh width/mesh height ratio. Despite quite a number of efforts, such hexagonal nettings are not known to the market at the time of filing the present document.
The objective of the invention is in particular to provide a generic steel wire netting made of high-tensile steel wires and having an improved mesh geometry, in particular improved mesh width/mesh height ratios. The objective is achieved according to the invention.
The invention is based on a steel wire netting, in particular a hexagonal netting, which is made of steel wires with hexagonal meshes, in particular for civil engineering purposes, preferably for an application in the field of protection from natural hazards, wherein the steel wires are alternatingly twisted with neighboring steel wires, preferably in a regular manner, and wherein the steel wires are formed of a high-tensile steel or at least have a wire core made of a high-tensile steel (e. g. high-tensile steel wires which are provided with an overlay or with a coating).
It is proposed that an—in particular average—ratio calculated from an, in particular average, mesh width of the hexagonal meshes and from an, in particular average, mesh height of the hexagonal meshes measured perpendicularly to the mesh width, amounts to at least 0.75, preferably to at least 0.8. This advantageously allows providing a steel wire netting made of high-tensile steel wires with a particularly advantageous mesh geometry, in particular a mesh geometry that is already widely in use and well proven in the non-high-tensile field. Advantageously, it is in this way possible to hold on to known and proven retaining properties of hexagonal nettings, which for example depend on rock sizes, while a strength, i. e. for example a tear resistance or rupture resistance, of the hexagonal netting may be increased considerably. Advantageously, as a result already existing planning and designs (e. g. of slope protection gabions, of coast protection gabions, of gully nets, of stone rolls, etc.), which up to now have used non-high-tensile hexagonal nettings with standard-compliant mesh sizes, can be improved and/or reinforced in a simple, uncomplicated manner (avoiding red tape), for example as the non-high-tensile hexagonal netting may be replaced, directly and without major changes, by a high-tensile hexagonal mesh netting having the same mesh geometry. It is for example advantageously possible that, with the slope protection gabions, the coast protection gabions, the gully nets and/or the stone rolls an identical filling material may be used, which in particular has an identical grain size of the filling material. This advantageously allows reducing cost as well as work input. In particular, the steel wire netting according to the invention cannot be produced either with known customary machines nor with the production device described in patent document PL 235814 B1. Further modifications and/or method steps, which are explained in the present document, are hence indispensably required for the production of the steel wire netting according to the invention.
In particular, the hexagonal meshes have shapes of at least substantially symmetrical hexagons. In particular, the hexagonal meshes in each case have a slightly elongated honeycomb shape. In particular, the hexagonal meshes form a gap-free tessellation in a netting plane of the steel wire netting. By “civil engineering purposes” are in particular purposes to be understood which comprise planning, execution performance and/or modification carried out on a construction. Examples for applications in a protection against natural hazards are the aforementioned gabions, like slope protection gabions, stone rolls, coast protection gabions or gully nets, but also cross-terrain spans, catchment fences, and the like.
In particular, an average value of a parameter, like for example an average mesh width/mesh height ratio, an average mesh width, an average mesh height, an average length of a twisted region of the steel wire netting that delimits a hexagonal mesh, an average length of a twisting, an average entry curvature of the steel wire in a transition from an at least substantially straight section of the steel wire that delimits a hexagonal mesh to a twisted region of the steel wire that delimits the hexagonal mesh, an average exit curvature of the steel wire in a transition from the twisted region of the steel wire that delimits the hexagonal mesh to an at least substantially straight further section of the steel wire that delimits the hexagonal mesh, and/or an average aperture angle of the hexagonal mesh, is created from an average value of several, in particular at least three, preferably at least five, preferentially at least seven and particularly preferably at least ten, meshes of the steel wire netting which have the parameter, wherein the meshes used for creating the average value are preferably not directly adjacent to each other.
A “mesh width” is in particular to mean a distance between two twisted regions of the steel wire netting which delimit a hexagonal mesh, which extend at least substantially parallel to each other and which are situated on opposite-situated sides of the hexagonal mesh. A “mesh height” is in particular to mean a distance between two corners of a hexagonal mesh of the steel wire netting, which are situated opposite each other in a direction parallel to a main extension direction of the twisted region. In particular, a twisting of the two steel wires delimiting the hexagonal mesh starts and/or ends at the corners of the hexagonal mesh between which the mesh height is measured. In particular, the mesh width of the hexagonal meshes of the steel wire netting is smaller than the mesh height of the hexagonal meshes of the steel wire netting. By a “main extension direction” of an object is herein in particular a direction to be understood which runs parallel to a longest edge of a smallest geometrical rectangular cuboid just still completely enclosing the object.
It is further proposed that the high-tensile steel of the steel wires has a tensile strength of at least 1,560 N/mm2, preferably of at least 1,700 N/mm 2 and preferentially of at least 1,950 N/mm2. This advantageously allows attaining especially high stability of the steel wire netting and/or of constructions made from/with the steel wire netting. Advantageously, in this way for example an especially favorable protection against natural hazards is achievable.
If, for example, the high-tensile steel of the steel wires at the same time has a tensile strength of maximally 2,150 N/mm2, it is advantageously possible to keep a brittleness of the steel wires of the steel wire netting, which increases with an increase in tensile strength, at a low level. Experiments have shown that—in particular when using steel wires which have tensile strengths in a narrow, specially selected range of tensile strengths between 1,700 N/mm2 and 2,150 N/mm2, preferably between 1,950 N/mm2 and 2,150 N/mm2—it is advantageously possible to create a particularly favorable balance between particularly high stability and at the same time limited brittleness. Such balance is especially advantageous, in particular for a utilization of the steel wire netting for the production of any kind of gabions. For example, this enables particularly high filling capacity, and thus particularly large and stable construction, of the gabions, which is at the same time particularly rupture-resistant in the case of an event, for example a rockfall, in which rocks fall on the gabions.
Furthermore, it is proposed that a length, in particular an average length, of a twisted region delimiting a hexagonal mesh is at least 30%, preferably at least 35% and preferentially at least 40% of the, in particular average, mesh height. This advantageously allows attaining particularly high stability of the steel wire netting. Advantageously, in this way a winding curvature in the twisted region of the hexagonal mesh can be kept in a (moderate) range in which a rupture risk of the high-tensile steel wire used is comparably low.
It is moreover proposed that a length, in particular an average length, of a twisted region delimiting a hexagonal mesh is at least 50%, preferably at least 55% and preferentially at least 60% of the, in particular average, mesh width. This advantageously allows attaining particularly high stability of the steel wire netting.
It is also proposed that that a length, in particular an average length, of a twisting within a twisted region delimiting a hexagonal mesh is less than 1.1 cm, preferably less than 1 cm, preferably with a diameter of the steel wires between 2 mm and 4 mm. This advantageously allows keeping a mesh height in a desired range without requiring too large entry curvatures and/or exit curvatures in a transition into/from the twisted region from/into the non-twisted region delimiting the hexagonal mesh. Advantageously, in this way and in particular together with the aforementioned minimum length of the twisted region, an especially favorable balance is achievable of a material-friendly winding curvature and material-friendly entry and exit curvatures, thus in particular enabling a high level of overall stability and/or overall rupture-resistance of the steel wire netting.
Preferably, in a transition from an at least substantially straight section of the steel wire that delimits a hexagonal mesh, to a twisted section of the steel wire that delimits a hexagonal mesh, an, in particular average, entry curvature of the steel wire is at least substantially equal to the, in particular average, exit curvature of the steel wire in a transition from the twisted region of the steel wire that delimits the hexagonal mesh to an at least substantially straight further section of the steel wire that delimits the hexagonal mesh. This advantageously allows achieving an especially high degree of symmetry of the hexagonal meshes, thus advantageously enabling particularly even load-bearing capacity in at least two pulling directions of the steel wire netting which are situated opposite each other along the mesh height, preferably in all directions of the wire netting. It is in this way advantageously possible to prevent installation mistakes, for example an installation of a non-symmetrical steel wire netting inverted by 180°. “Substantially equal” is to mean, in this context, with a deviation of the curvature radii of the curvatures that is in particular less than 20%, preferably less than 15%, advantageously less than 10%, preferentially less than 5% and especially preferentially less than 2.5%. Preferably, in the transition from the at least substantially straight section of the steel wire that delimits the hexagonal mesh to the twisted region of the steel wire that delimits the hexagonal mesh, the steel wires bend to an at least substantially equal extent as in the transition from the twisted region of the steel wire that delimits the hexagonal mesh to the at least substantially straight further section of the steel wire that delimits the hexagonal mesh. “To bend to an at least substantially equal extent” is in particular to mean, in this context, that bends which are visible in a view from above onto the steel wire netting have bending angles in the transitions which differ by less than 20%, preferably by less than 15%, advantageously by less than 10%, preferentially by less than 5% and particularly preferably by less than 2.5%.
In addition, it is proposed that a twisted region delimiting a hexagonal mesh comprises more than three consecutive twistings, which in particular have the same direction. This in particular allows attaining high stability of the steel wire netting. Advantageously it is moreover possible to reduce a probability of complete untwisting of a twisted region in the case of a wire rupture in the twisted region. Preferably the twisted region delimiting the hexagonal mesh comprises at least five or at least seven consecutive twistings, which preferably have the same direction. By a “twisting” is in particular an 180°-wrapping of one the steel wires by the neighboring steel wire. Preferably a firm screw-like winding of two wires around each other, with a wrapping of both wires by 180°, is to be understood as a twisting. In the case of three consecutive twistings, each steel wire is thus wound around by the respectively other steel wire by 540° (five-fold: 900°, seven-fold: 1260°).
If preferably at least one, in particular average, aperture angle of the hexagonal mesh, spanning the hexagonal mesh in a longitudinal direction, is at least 70°, preferably at least 80° and preferentially at least 90°, advantageously a high degree of stability is enabled while maintaining the advantageous mesh width/mesh height ratio of 0.75. Advantageously, the advantageous mesh width/mesh height ratio of 0.75 or more is achievable with twisted regions which at the same time have sufficient length, thus avoiding wire rupture. The aperture angle spanning the hexagonal mesh in the longitudinal direction is in particular the angle spanned by the (non-twisted) steel wires in the corner in which the two steel wires meet or separate which together delimit the hexagonal mesh (all around). In particular, the hexagonal mesh has two aperture angles spanning the hexagonal mesh in the longitudinal direction. In particular, the two aperture angles spanning the hexagonal mesh in the longitudinal direction are at least 70°, preferably at least 80° and preferentially at least 90°. In particular, the two aperture angles spanning the hexagonal mesh in the longitudinal direction are at least substantially equal. “Substantially equal” is in particular to mean, in this context, a congruence of the aperture angles in terms of size with a maximal deviation of 8°, preferably of 6°, advantageously of 4° and preferentially of 2°. The longitudinal direction of the hexagonal mesh in particular extends parallel to the main extension direction of the hexagonal mesh.
So, if the opposite-situated, in particular middle, aperture angles of the hexagonal mesh, which span the hexagonal mesh in the longitudinal direction, differ from each other by maximally 8°, preferably by maximally 6°, preferentially by maximally 4°, advantageously a high level of symmetry of the steel wire netting, in particular of the hexagonal meshes, is achievable, as a result of which it is advantageously possible to attain especially even load-bearing capacity in at least two pulling directions of the steel wire netting which are situated opposite each other along the mesh height, preferably in all directions of the steel wire netting.
If the hexagonal meshes have an, in particular average, mesh width of approximately 60 mm, approximately 80 mm or approximately 100 mm, it is advantageously possible to obtain high and quick acceptance of the steel wire netting in planning and construction projects. Advantageously, in this way simple reinforcement of already planned or designed constructions will be enabled, in particular due to particularly simple re-planning. In particular, the hexagonal meshes have a mesh size and/or mesh shape compliant with the standard EN 10223-3:2013. In particular, the steel wire herein has a diameter of 2 mm, 3 mm, 4 mm or with a value between 2 mm and 4 mm.
If moreover the high-tensile steel of the steel wires is implemented of a stainless type of steel or at least has a sheath made of a stainless type of steel, it is possible to maintain particularly high corrosion resistance and hence a particularly long lifetime of the constructions comprising the steel wire netting. Lifetimes of 100 years and more tend to be requested by customers, and are theoretically achievable by a utilization of stainless types of steel. In particular, the steel wire is made of a stainless steel having a material number according to the standard DIN EN 10027-2:2015-07 which is between 1.4001 and 1.4462, for example of a stainless steel having one of the DIN EN 10027-2:2015-07 material numbers 1.4301, 1.4571, 1.4401, 1.4404 or 1.4462.
If alternatively the steel wires have a corrosion protection coating or a corrosion protection overlay, it is also advantageously possible to achieve high corrosion resistance together with a long lifetime, wherein costs can be kept at a low level in comparison to stainless steel wires. In particular, the corrosion protection coating is realized as a galvanization, as a ZnAl coating, as a ZnAlMg coating or as a comparable metallic corrosion protection coating. In particular, the corrosion protection overlay is realized as a non-metallic overlay surrounding the steel wire in a circumferential direction, for example as a plastic envelope (e. g. PVC) or as a graphene envelope.
It is further proposed that the corrosion protection coating is realized at least as a class B corrosion protection coating according to the standard DIN EN 10244-2:2001-07, preferably as a class A corrosion protection coating according to the standard DIN EN 10244-2:2001-07. This advantageously allows attaining particularly high corrosion resistance and thus a long lifetime. Preferably not only the starting materials, i. e. the non-bent steel wires, have the class B or class A corrosion protection coating but the finished steel wire netting as well. In particular, in a test run with an alternating climate test, at least a portion of the steel wire netting with the corrosion protection layer has a corrosion resistance of more than 1,680 hours, preferably of more than 2,016 hours, advantageously of more than 2,520 hours, preferentially of more than 3,024 hours and particularly preferentially of more than 3,528 hours. An “alternating climate test” is in particular to mean a corrosion resistance test of the corrosion protection, in particular of the corrosion protection layer, preferably following the specifications given by VDA [German Association of the Automotive Industry] in their Recommendation VDA 233-102, which in particular provides, at least in a sub-period, a fogging and/or spraying of at least one test piece with a salt spray fog and/or exposing the test piece, at least in a sub-period, to a temperature change from room temperature to sub-zero temperatures. By varying a temperature, a relative humidity and/or a salt concentration which the test piece is exposed to, it is advantageously possible to improve a reliability of a test method. In particular, test conditions can be adapted closer to real conditions which the wire netting device is exposed to, in particular when used in the field. The test piece is preferably embodied as a sub-portion of a wire that is at least substantially identical to the wire of the wire netting device, preferentially as a sub-portion of the wire of the wire netting device. The alternating climate test is preferably carried out in accordance with the customary edge conditions for alternating climate tests, which are known to anyone skilled in the art and which are in particular listed in VDA Recommendation 233-102 of Jun. 30, 2013. The alternating climate test is in particular carried out in a test chamber. The conditions in an interior of the test chamber during the alternating climate test are in particular strictly controlled conditions. In particular, strict specifications regarding temperature profiles, relative air humidity and periods of fogging with salt spray fog must be followed in the alternating climate test. A test cycle of the alternating climate test is in particular divided into seven cycle sections. A test cycle of the alternating climate test in particular takes one week. One cycle section in particular takes one day. A test cycle comprises three different test sub-cycles. A test sub-cycle implements a cycle section. The three test sub-cycles comprise at least one cycle A, at least one cycle B and/or at least one cycle C. During a test cycle, test sub-cycles are realized consecutively in the following order: cycle B, cycle A, cycle C, cycle A, cycle B, cycle B, cycle A.
Cycle A in particular comprises a salt spraying phase. In the salt spraying phase a salt spray fog is in particular sprayed within the test chamber. In particular, the salt solution sprayed during cycle A is here in particular realized as a solution of sodium chloride in distillated water, which was preferably boiled prior to a preparation of the solution and which preferentially has an electrical conductivity of maximally 20 μS/cm at (25±2) ° C., with a mass concentration in a range of (10±1) g/l. The test chamber for the alternating climate test in particular has an inner volume of at least 0.4 m3. In particular in an operation of the test chamber, the inner volume is homogeneously filled with a salt spray fog. The upper portions of the test chamber are preferably implemented in such a way that drops formed on the surface cannot fall onto a test piece. Advantageously a temperature is (35±0.5°) C. during a spraying of the salt spray fog, in particular within the test chamber, the temperature being preferably measured at a distance of at least 100 mm from a wall of the test chamber.
Cycle B in particular comprises a work phase, during which the temperature is maintained at room temperature (25° C.) and the relative humidity is maintained at a room-typical relative air humidity (70%). In the work phase in particular the test chamber can be opened and the test piece can be assessed and/or checked.
Cycle C in particular comprises a freezing phase. In the freezing phase in particular the test chamber temperature is maintained at a value below 0° C., preferably at −15° C.
A “corrosion resistance” is in particular to be understood as a durability of a material during a corrosion test, for example an alternating climate test, in particular in accordance with VDA recommendation 233-102 of Jun. 30, 2013, during which a functionality of a test piece is maintained, and/or preferably a time duration during which a threshold value of a corrosion parameter of a test piece is undershot during an alternating climate test. By “a functionality being maintained” is in particular to be understood that material properties of a test piece which are relevant for a functionality of a wire netting, like a tear resistance and/or brittleness, remain substantially unchanged. By “a material property remain[ing] substantially unchanged” is in particular to be understood that a change in a material parameter and/or in a material property amounts to less than 10%, preferably less than 5%, preferentially less than 3% and especially preferentially less than 1% with respect to an initial value prior to the corrosion test. Preferably the corrosion parameter is implemented as a percentage of an overall surface of a test piece, on which dark brown rust (DBR) is, in particular visually, perceivable. The threshold value of the corrosion parameter is preferably 5%. A corrosion resistance thus preferably indicates a time interval which passes until dark brown rust (DBR) is visually perceivable on 5% of an overall surface of a test piece, in particular an overall surface of a test piece that is exposed to the salt spray fog in the alternating climate test. Preferentially the corrosion resistance is the time that passes between a start of the alternating climate test and an occurrence of 5% DBR on the surface of the test piece.
In particular, already the production method of the corrosion-protection-coated steel wire nettings used is specifically adapted, such that the resulting steel wires have a high rupture resistance despite high tensile strengths and despite thick corrosion protection layers, and in particular survive the production process for the steel wire netting such that the resulting steel wire netting is free of rupturing and the corrosion protection layer remains unscathed. For this purpose, for example the coating temperature is specifically selected such that additional brittling of the coated high-tensile steel wires can be kept low. For this purpose, for example in a galvanization the temperature of the coating bath is specifically kept lower than usual. In particular, the temperature of the coating bath herein remains in each process step below 440° C., preferably below 435° C., advantageously below 430° C., preferentially below 425° C. At the same time the coating temperature of the coating bath herein remains above 421° C. In particular, extensive temperature control of the coating bath is necessary for this. In particular, additional leaking of carbon from the high-tensile steel wires during the coating process, influencing brittleness and strength of the steel wire, is taken into account here. Moreover, a production method for the steel wire netting from the coated steel wires is preferably adapted specifically in such a way that a rupturing of the steel wire or a damaging of the corrosion protection layer while braiding the hexagonal meshes is prevented to the best possible extent. For this, in particular a twisting speed at which neighboring steel wires are twisted is reduced as compared to customary production processes. In particular, the twisting speed is at least 0.5 seconds per (180°) twisting, preferably at least 0.75 seconds per (180°) twisting and preferentially at least one second per (180°) twisting.
In the case of a steel wire with a class B corrosion protection coating and with a wire diameter of approximately 2 mm, the area density of the corrosion protection layer is at least 115 g/m2. In the case of a steel wire with a class B corrosion protection coating and with a wire diameter of approximately 3 mm, the area density of the corrosion protection layer is at least 135 g/m2. In the case of a steel wire with a class B corrosion protection coating and with a wire diameter of approximately 4 mm, the area density of the corrosion protection layer is at least 135 g/m2. In the case of a steel wire with a class B corrosion protection coating and with a wire diameter of approximately 5 mm, the area density of the corrosion protection layer is at least 150 g/m2. In the case of a steel wire with a class A corrosion protection coating and with a wire diameter of approximately 2 mm, the area density of the corrosion protection layer is at least 205 g/m2. In the case of a steel wire with a class A corrosion protection coating and with a wire diameter of approximately 3 mm, the area density of the corrosion protection layer is at least 255 g/m2. In the case of a steel wire with a class A corrosion protection coating and with a wire diameter of approximately 4 mm, the area density of the corrosion protection layer is at least 275 g/m2. In the case of a steel wire with a class A corrosion protection coating and with a wire diameter of approximately 5 mm, the area density of the corrosion protection layer is at least 280 g/m2.
In particular, the steel wire used and the corrosion protection layer applied onto the steel wire survive, in particular in at least one test run, without damages, in particular without rupturing, an N-fold twisting of the wire, wherein N may be determined, if applicable by rounding down, as B*R−0.5·d−0.5, and d is a diameter of the wire in mm, R is a tensile strength of the wire in N*mm−2 and B is a factor of at least 960 N0.5 mm−0.5, preferably at least 1,050 N0.5 mm−0.5, advantageously at least 1,200 N0.5 mm−0.5, preferentially at least 1,500 N0.5 mm−0.5, and especially preferentially at least 2,000 N0.5 mm−0.5. In particular, the twisting test is executed in accordance with the requirements of the standards DIN EN 10218-1:2012-03 and DIN° EN° 10264-2:2012-03. This in particular allows providing a selection process for a suitable wire that is significantly more strict and more specific with regard to a load-bearing capacity as compared to a twisting test in accordance with the standards DIN EN 10218-1:2012-03 and DIN° EN° 10264-2:2012-03. A “twisting” is in particular to mean a twisting of a clamped-in wire around a longitudinal axis.
In particular, the steel wire used and the corrosion protection layer applied onto the steel wire survive, in particular in at least one test run, without damages, in particular without rupturing, an M-fold back-and-forth bending of the wire around at least one bending cylinder that has a diameter of maximally 8d, preferably no more than 6d, preferentially maximally 4d and particularly preferably no more than 2d, by at least 90° respectively, in opposite directions, wherein M can be determined, if applicable by rounding-down, to be C*R−0.5*d−0.5, and wherein d is a diameter of the wire in mm, R is a tensile strength of the wire given in N mm−2 and C is a factor of at least 350 N0.5 mm−0.5, preferably at least 600 N0.5 mm−0.5, advantageously at least 850 N0.5 mm−0.5, preferentially at least 1,000 N0.5 mm−0.5 and particularly preferably at least 1,300 N0.5 mm−0.5. In particular, the reverse bend test is executed in accordance with the standards DIN EN 10218-1:2012-03 and DIN° EN° 10264-2:2012-03. This in particular allows providing a selection process for a suitable wire that is considerably stricter and/or more specific regarding a load-bearing capacity than a reverse bend test according to the standards DIN EN 10218-1:2012-03 and DIN° EN° 10264-2:2012-03. In the reverse bending, the wire is preferably bent around two opposite-situated bending cylinders which are implemented identically.
Beyond this it is proposed that at least two sub-pieces of the steel wires survive without rupturing, in particular in a test run, a screw-like winding around each other, comprising at least N+1 twistings, preferably N+2 twistings and preferentially N+4 twistings, wherein N is (if applicable by rounding down) a number of twistings of the steel wires delimiting the hexagonal meshes to opposite sides. This advantageously permits ensuring a high rupture resistance of the steel wire netting, in particular also in the case of events initiating additional deformation of the steel wire nettings. It is moreover advantageously possible to make sure that the steel wires used for the production of the steel wire netting do not rupture during the production process, in particular not during a twisting, thus causing production stoppage and/or damaging of production installations. It is moreover advantageously possible to make sure that an overbending of the steel wires used, which is necessary for the production of the steel wire netting having the advantageous mesh width/mesh height ratio of at least 0.75, is feasible, thus basically enabling a production of the steel wire netting having the advantageous mesh width/mesh height ratio of at least 0.75.
Furthermore, a production device is proposed for braiding a steel wire netting with hexagonal meshes, in particular a hexagonal netting, from steel wires comprising a high-tensile steel, with at least one array of twisting units for an alternating twisting of steel wires with further steel wires which are guided on respectively opposite sides of the steel wires, and with at least one rotatable roller, which is supported downstream of the twisting units and has on a sheath surface dogs which are configured to engage into the newly braided hexagonal meshes, thus pushing or pulling the steel wire netting forward, wherein the twisting units are configured to over-rotate the steel wires and/or the rotatable roller is configured to over-expand a mesh width of the hexagonal meshes, in particular as compared to the mesh width of a finished hexagonal mesh. Advantageously, a production of a steel wire netting from high-tensile steel wires with an improved mesh geometry, in particular with standard-compliant mesh width/mesh height ratios, is enabled in this way. In particular, the twisting units are configured to produce the twisted regions which partly delimit the hexagonal meshes. In particular, each twisting unit comprises two half-shell twisting elements, each of which guides a steel wire and which are alternatingly rotated around a shared rotation axis and around two separate rotation axes for a twisting, wherein in particular in rotating separately from each other, each of the half-shells is combined with a half-shell of a neighboring twisting unit. In particular, a rotation axis of the rotatable roller is oriented at least substantially perpendicularly to the rotation axes of the twisting units. By the twisting units being configured to “over-rotate” the steel wires, is in particular to be understood that a rotation angle swept over by the twisting units during a twisting process is larger than a total twisting angle of the twisted regions delimiting the hexagonal meshes of the finished steel wire netting. By the rotatable roller being configured to “over-expand” the mesh width of the hexagonal mesh, is in particular to be understood that a mesh width enforced on the steel wire netting by the rotatable roller, in particular by the dogs of the rotatable roller, is larger than a mesh width of the hexagonal meshes of the finished steel wire netting. “Configured” is in particular to mean specifically designed and/or equipped. By an object being configured for a certain function is in particular to be understood that the object fulfills and/or executes said certain function in at least one application state and/or operation state.
If herein the over-rotating of the intertwisted steel wires and/or the over-expanding of the hexagonal meshes is configured to compensate a rebound of the high-tensile steel wires, which are substantially more elastic as compared to a non-high-tensile steel, advantageously a production of a steel wire netting from high-tensile steel wires is enabled with an improved mesh geometry, in particular with standard-compliant mesh width/mesh height ratios, which was not possible with customary methods. In particular, a dimension of an over-rotating/twisting is selected such that a rebound effect that corresponds to the material, the tensile strength and the wire thickness of the respective steel wire used is compensated as completely as possible.
In this context it is proposed that the twisting units are configured to twist the steel wires at least M-fold with one another, wherein M is given by the formula M=U+0.5*G, and U is an uneven integer ≥3, which preferably corresponds to a number of twistings within a twisted region of the finished steel wire netting that delimits a hexagonal mesh, and wherein G is any real number ≥1 and ≤3. As a result, sufficient compensation of the rebound effect of the high-tensile steel wire, in particular having a thickness between 2 mm and 4 mm, is advantageously attainable. Preferably G≥1.5, preferably ≥2.
In a further aspect of the invention which, taken on its own or in combination with at least one, in particular in combination with one of the remaining aspects of the invention, in particular in combination with any number of the remaining aspects of the invention, it is proposed that the production device comprises a stretching unit, which is integrated in the rotatable roller, which is supported downstream of or is arranged separately from the rotatable roller, and which is configured to stretch a finished steel wire netting, in particular hexagonal netting, at least in a direction parallel to the mesh width, preferably at least by 30%, preferably at least by 50% and particularly preferably at least by 55%. In particular, the stretching unit is configured to simultaneously grip and stretch several meshes of the steel wire netting which are arranged behind one another or spaced apart behind one another in a direction running parallel to the mesh width. Preferentially at least a large portion of all hexagonal meshes of the mesh netting is stretched directly. By the term “stretched directly” is in particular to be understood that the stretching unit contacts the meshes directly and stretches them independently from a stretching of further meshes. A “large portion” is in particular to mean 10%, preferably 20%, advantageously 30%, especially advantageously 50%, preferentially 66% and particularly preferentially 85%.
Moreover, a production method is proposed for a braiding of a steel wire netting with hexagonal meshes, in particular a hexagonal netting, in particular by means of a production device. This advantageously allows providing a steel wire netting made of high-tensile steel wires with a particularly advantageous mesh geometry, which is in particular already widely in use and well proven in the non-high-tensile field.
If during production of the steel wire netting the steel wires are over-rotated in twisted regions of the steel wire netting and/or if the hexagonal meshes are over-expanded in a direction parallel to the mesh width, this advantageously enables a production of a steel wire netting from high-tensile steel wires with an improved mesh geometry, in particular with standard-compliant mesh width/mesh height ratios, which was not realizable with methods known until now.
The steel wire netting according to the invention, the production device according to the invention and the production method according to the invention shall herein not be limited to the application and implementation described above. In particular, in order to realize a functionality that is described here, the steel wire netting according to the invention, the production device according to the invention and the production method according to the invention may comprise a number of individual elements, components and units that differs from a number given here.
Further advantages will become apparent from the following description of the drawings. In the drawings four exemplary embodiments of the invention are illustrated. The drawings, the description and the claims contain a plurality of features in combination. Someone skilled in the art will purposefully also consider the features separately and will find further expedient combinations.
It is shown in:
In order to form the hexagonal meshes 16a, the steel wires 10a, 12a, 14a of the steel wire netting 54a are alternatingly twisted with neighboring steel wires 10a, 12a, 14a of the steel wire netting 54a. The intertwisted steel wires 10a, 12a, 14a form twisted regions 24a. The twisted regions 24a in each case comprise at least three consecutive twistings 28a, 38a, 40a. Each twisting 28a, 38a, 40a comprises a 180° winding of a steel wire 10a, 12a, 14a of the steel wire netting 54a around a further steel wire 10a, 12a, 14a of the steel wire netting 54a. In the example shown in
The hexagonal meshes 16a of the steel wire netting 54a have a mesh height 20a. The mesh height 20a is measured perpendicularly to the mesh width 18a. The mesh height 20a is implemented as a largest aperture length of the hexagonal meshes 16a. The mesh height 20a is measured between a corner 66a of the hexagonal mesh 16a, in which a twisting 28a, 38a, 40a (differing from the twisted regions 24a) of the two steel wires 10a, 12a, which delimit the hexagonal mesh 16a all around, starts, and a further corner 68a of the hexagonal mesh 16a, in which the twisting 28a, 38a, 40a (differing from the twisted regions 24a) of the steel wires 10a, 12a, which delimit the hexagonal mesh 16a all around, ends.
The twisted regions 24a respectively delimit the hexagonal meshes 16a on two opposite-situated sides. Each twisted region 24a (possible exception: an edge of the steel wire netting 54a) delimits two neighboring hexagonal meshes 16a at the same time. Each of the twisted regions 24a has a length 22a. The lengths 22a of the twisted regions 24a are approximately equal. The average length 22a of the twisted regions 24a delimiting the hexagonal meshes 16a amounts to at least 30% of the average mesh height 20a of several hexagonal meshes 16a of the steel wire netting 54a.
The hexagonal meshes 16a of the steel wire netting 54a have a mesh width 18a. The mesh width 18a is implemented as a shortest distance between the two twisted regions 24a delimiting a hexagonal mesh 16a. The average length 22a of the twisted regions 24a delimiting the hexagonal meshes 16a amounts to at least 50% of the average mesh width 18a of several hexagonal meshes 16a of the steel wire netting 54a. The average mesh width 18a of the hexagonal meshes 16a typically amounts to approximately 60 mm, approximately 80 mm or approximately 100 mm. In the case shown exemplarily in
An average ratio of the average mesh width 18a of several hexagonal meshes 16a of the steel wire netting 54a and the average mesh height 20a of the hexagonal meshes 16a is at least 0.75. A mesh width/mesh height ratio formed from the mesh width 18a and the mesh height 20a is at least 0.75. In the case shown exemplarily in
The hexagonal meshes 16a have a first aperture angle 44a that spans the hexagonal meshes 16a in a longitudinal direction 42a of the hexagonal meshes 16a. The longitudinal direction 42a points in a production direction of the steel wire netting 54a, i. e. from a twisted region 24a that was produced later towards a twisted region 24a that was produced earlier. Alternatively, the longitudinal direction 42a may point in the opposite direction. The first aperture angle 44a spans the hexagonal mesh 16a in a corner 66a that is situated further frontwards in the longitudinal direction 42a. The hexagonal meshes 16a have a second aperture angle 70a that spans the hexagonal meshes 16a in the longitudinal direction 42a. The second aperture angle 70a spans the hexagonal mesh 16a in a corner 68a that is situated further rearwards in the longitudinal direction 42a. The two aperture angles 44a, 70a are situated in opposed corners 66a, 68a of the hexagonal meshes 16a.
The average first aperture angle 44a of several hexagonal meshes 16a of the steel wire netting 54a is at least 70°. In the example shown in
Viewed along the longitudinal direction 42a, the two steel wires 10a, 12a, which delimit a hexagonal mesh 16a of the steel wire netting 54a all around, in each case have an entry curvature 30a on respectively opposite-situated sides of the hexagonal mesh 16a, in a transition 72a in which the respective steel wire 10a, 12a passes from an at least substantially straight section 32a of the respective steel wire 10a, 12a that delimits the hexagonal mesh 16a to a twisted region 24a of the steel wire 10a, 12a that delimits the hexagonal mesh 16a. Viewed along the longitudinal direction 42a, the two steel wires 10a, 12a, which delimit a hexagonal mesh 16a of the steel wire netting 54a all around, in each case have an exit curvature 34a on respectively opposite sides of the hexagonal mesh 16a, in a further transition 74a (differing from the transition 72a) in which the respective steel wire 10a, 12a passes from the twisted region 24a that delimits the hexagonal mesh 16a to an at least substantially straight further section 36a of the steel wire 10a, 12a that delimits the hexagonal mesh 16a. The average entry curvature 30a and the average exit curvature 34a of the steel wires 10a, 12a, 14a of several hexagonal meshes 16a are approximately equal.
The steel wires 10a, 12a, 14a of the steel wire netting 54a have a rupture resistance suitable for the production of the hexagonal meshes 16a with the mesh width/mesh height ratio of 0.75 or more. The steel wires 10a, 12a, 14a of the steel wire netting 54a are realized in such a way that two sub-pieces of the steel wires 10a, 12a, 16a survive in a first twisting test run a screw-like winding around each other comprising at least N+1 twistings, wherein N is, if applicable by rounding down, a number of twistings of the steel wires 10a, 12a, 14a delimiting the hexagonal meshes 16a to opposite sides. In the example shown in
Moreover, the steel wires 10a, 12a of the steel wire netting 54a are realized in such a way that in a second twisting test run two sub-pieces of the steel wires 10a, 12a, 14a survive a screw-like winding and unwinding of the steel wires 10a, 12a, 14a around each other, comprising at least three, preferably at least five and preferentially at least seven back-and-forth twistings. The test pieces of the steel wires 10a, 12a, 14a are herein alternatingly wrapped with each other by respectively 180° and then unwrapped. An 180° twisting in one of the two twisting directions is herein counted as one back-and-forth twisting. For an execution of the second twisting test run, the two sub-pieces of the steel wires 10a, 12a, 14a of the steel wire batch are also clamped into the test device 76a at opposite ends and are twisted back and forth until a wire rupture of at least one of the steel wires 10a, 12a, 14a is detected. This advantageously allows, on the one hand, ensuring that the steel wires 10a, 12a, 14a do not break during the production of the steel wire netting 54a according to the invention, in particular in an over-rotating of the steel wires 10a, 12a, 14a and/or do not break in an over-expansion of the steel wire netting 54a. On the other hand, it is in this way advantageously possible to state that the wire netting 54a according to the invention is capable of providing a sufficient protective effect as it has, for example, a sufficiently high rupture resistance also in the case of an event (for example a rockfall) involving plastic and/or elastic deformation.
The production device 52a comprises an array of twisting units 56a, 58a (see also
The twisting units 56a, 58a, 104a are configured to over-rotate the steel wires 10a, 12a, 14a during the twisting process in which the steel wires 10a, 12a, 14a are twisted with each other in order to form the twisted regions 24a. The over-rotation of the intertwisted steel wires 10a, 12a, 14a is configured to compensate, after the twisting process, a rebound of the high-tensile steel wires 10a, 12a, 14a, which are considerably more elastic as compared to a non-high-tensile steel. The over-rotation of the intertwisted steel wires 10a, 12a, 14a is configured for producing a planar steel wire netting 54a with hexagonal meshes 16a, which has narrowly wrapped twisted regions 24a. The twisting units 56a, 58a, 104a are configured for twisting the steel wires 10a, 12a, 14a with each other in the twisting process at least M-fold, wherein M is given by the formula M=U+0.5*G, and U is an uneven integer ≥3, and G is any real number ≥1 and ≤3. In the case shown by way of example, the twisting units 56a, 58a, 104a are configured for twisting the steel wires 10a, 12a, 14a in the twisting process more than 3.5-fold. In the case shown by way of example, the twisting units 56a, 58a, 104a are configured for twisting the steel wires 10a, 12a, 14a in the twisting process approximately 4-fold.
The rotatable roller 60a comprises on a sheath surface 62a dogs 64a. The dogs 64a are configured to engage into the newly braided hexagonal meshes 16a of the steel wire netting 54a, thus pushing or pulling the steel wire netting 54a forward in the running twisting process. The rotatable roller 60a is configured to over-expand the hexagonal meshes 16a in a direction of the mesh width 18a in comparison to the mesh width 18a of a finished hexagonal mesh 16a. The dogs 64a are configured to over-expand the hexagonal meshes 16a in the direction of the mesh width 18a. The dogs 64a have a shape which generates an over-expansion of the hexagonal meshes 16a in the direction of the mesh width 18a. A width of each dog 64a of the rotatable roller 60a is larger than the mesh width 18a of the finished steel wire netting 54a. The over-expansion of the hexagonal meshes 16a is configured to compensate a rebound of the high-tensile steel wires 10a, 12a, 14a, which are considerably more elastic as compared to a non-high-tensile steel.
In at least one further method step 120a the one (tested) steel wire 10a is fed to the first twisting unit 56a. In the method step 120a, the further (tested) steel wire 12a is fed to the first twisting unit 56a. In at least one method step 124a, the two steel wires 10a, 12a are twisted with each other. In the production of the steel wire netting 54a, in the method step 124a, the steel wires 10a, 12a are over-rotated in the twisted regions 24a of the steel wire netting 54a. In the method step 124a the steel wires 10a, 12a are over-rotated in the twisted regions 24a of the steel wire netting 54a at least by a half twist, preferably at least by a full twist. After the over-rotation the over-rotated steel wires 10a, 12a automatically rebound by the over-rotated amount due to the high elasticity of high-tensile steel, such that the geometry according to the invention of the hexagonal meshes 16a is brought about.
In at least one further method step 118a the steel wire netting 54a that is being created is attacked at the twisted regions 24a by the dogs 64a of the rotatable roller 60a and is taken along with the movement of the rotatable roller 60a. By the dogs 64a, in particular by the engagement of the dogs 64a in the hexagonal meshes 16a, the hexagonal meshes 16a are in the method step 118a over-expanded in directions parallel to the mesh width 18a. After passing the rotatable roller 60a, the over-expanded hexagonal meshes 16a automatically rebound at least by a portion of the expansion due to the high elasticity of high-tensile steel, such that the geometry according to the invention of the hexagonal meshes 16a is brought about.
Alternatively or additionally, in at least one further method step 126a the hexagonal meshes 16a of the finished steel wire netting 54a are additionally or alternatively stretched. In the method step 126a the hexagonal meshes 16a of the finished steel wire netting 54a are stretched by the stretching elements 112a, 114a, 116a which are integrated in the rotatable roller 60a or by stretching elements 112a, 114a, 116a which are implemented separately from the rotatable roller 60a. After the stretching by the stretching unit 134a, the stretched hexagonal meshes 16a automatically rebound at least by a portion of the stretching due to the high elasticity of high-tensile steel, such that the geometry according to the invention of the hexagonal meshes 16a is brought about.
In
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 100 678.3 | Jan 2021 | DE | national |
This application is a U.S. national stage application of PCT/EP2022/050445 filed on Jan. 11, 2022, which claims priority from and incorporates herein by reference the German patent application DE 10 2021 100 678.3 filed on Jan. 14, 2021.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/050445 | 1/11/2022 | WO |
