Plants for electrowelded wire mesh

Plants for electrowelded wire mesh
Plants for production of electrowelded mesh. Continuosly fed with coil or with pre-cut rebar charged manually.

MRSA
Highly flexible electronically-programmable plant for the automatic production of both standard and special electro-welded mesh panels from pre-straightened and pre-cut bars for the line-wire and cross-wire requirements. Modular conception allows a variety of configurations according to the specific production requirement, grouping together the various devices to the main components of the machine, such as the welding unit and the automatic cross-wire loader.
The plant is hence designed to meet the needs of mesh producers wishing to undertake a limited investment who do not envisage high volume production runs. In addition it is also for medium and large size producers, wishing to complement their production capabilities with a “wild card” plant suitable for non-standard mesh types, hence allowing them to address small production runs and gain greater internal flexibility enabling them to offer a more complete service to their clientele.

MRV
A completely automatic and electronically-programmable plant for the production of standard electrowelded mesh, in panel or coil format. The line-wires and cross-wires are weldeable wire, smooth or ribbed, supplied from coils or spools (alternatively, certain models can be supplied from pre-straightened cut-to-length bars) within the possible diameter range.
The MRV-1 and MRV-TWIN plants allow the insertion of one or two cross-wires simultaneously for the production of a single panel or coil at a time. The MRV-2 models produce two panels at the same time, one on top of the other which hence obviates the need for any rotating device for stacking.
The adoption of these innovative systems guarantees maximum flexibility and quality within the ambit of specific production requirements.

MRV-2
The MRV-2 plant is a high speed fully automatic off-coil machine targeted for the production of mesh in panel format where both the line and cross wire requirements are met directly from coil material of either smooth or ribbed cold drawn/rolled wire or hot rolled wire.
The key characteristic of the MRV-2 plant lies in the combination of its vertical twin welding head system and twin cross wire insertion system designed to produce two identical mesh panels at the same time. This feature means that the traditional panel turning and stacking unit is no longer required implying a lower initial investment outlay, fewer down-times, shorter set-up times, simpler operation and overall lower maintenance and running costs.
The use of simple, efficient but very effective solutions based on servo motor technology throughout the machine as well as the unique patented cross wire straightening and feeding system, makes the MRV-2 range of machines highly attractive from all aspects of price, quality, reliability and productivity as well as allowing great flexibility overall, be it in the type of meshes to be produced or in the range of diameters to be processed.
Obviously the MRV-2 plant can be coupled to a variety of complimentary accessories such as automatic mesh pack tying devices or intermediate buffer mesh packs stacking systems and others according to specifc client requirements.

The coil material can be positioned in either vertical or horizontal payoff units.
The line wires pass through various consecutive processing stages which include the wire detection unit, a pulling and unwinding unit, the straightening systems, the tension control loop cages, the final straightening blocks and the twin independent roller feeding device.
The same occurs to the two cross wires which after passing through the unwinding and pulling units, the initial straightening systems, and the tension control cages are inserted with the special patented straightening and feeding device directly into the revolving cross wire positioning systems in the welding unit; this patented device is especially ideal for guaranteeing quality of end product when processing different types of material such as hot rolled wire. The vertical twin welding head ensures a fast and optimal welding of the cross wires with the line wires to form two identical mesh panels. The two mesh panels are guided simultaneously from the welding unit into the mesh shearing device.

Because the MRV-2 machine does not require a panel turning and stacking unit the mesh panels are automatically correctly deposited and stacked on the evacuation systems immediately after the cut. This allows a full optimization of the production speeds with any type or size of mesh panel. A variety of evacuation systems are available according to client requirements.

The high productivity MRV-2 plant lends itself to further automization downstream with optional accessories such as the automatic mesh pack tying device and the intermediate buffer mesh packs stacking system.

Various models of MRV-2 are available to cater for a variety of wire size ranges which fall between 3,4mm and 12mm. The plant can cater for different maximum mesh lengths on request and different models of MRV-2 machines can be configured for different maximum mesh widths, up to 3 meters, depending on client requirements. Production speeds in excess of 240 strokes per minute are available as are different configurations to suit different production requirements in terms of internal pitch sizes and mesh typologies.

TWIN WELD
The “Twinweld” range comprises completely automatic and electronically-programmable plants for the production of standard electrowelded mesh elements, in panel or roll format. The line- and cross-wires are prepared with weldable wire from coil or spool, within the allowed diameter range.
The plants are fitted with a new type of welding head which employs a system of cross-wire insertion and positioning which is highly efficient and performance enhancing.
The plants are flexible in that they allow the use of one or two welding heads, according to the desired production requirements (it may even be agreed in advance to have the second head added at only a later stage).
The different systems for the stacking and storage of the mesh panels and rolls are modular, allowing the plant to be configured in a variety of ways, as desired.

The enhanced design flexibility allows the following configurations:
P-Weld: single welding head for production of mesh in flat panels;
C-Weld: single welding head for production of mesh in rolls;
CombiWeld: single welding head for production of mesh in flat panels and rolls;
Twin P-Weld: double welding head for production of mesh in flat panels;
Twin C-Weld: double welding head for production of mesh in rolls;
TwinWeld: double welding head for the production of mesh in flat panels and rolls.

WELDPLUS
The Weldplus plant is the latest generation of highly flexible and fully automatic off-coil machines targeted for the production of any type of mesh in panel format. Both the line and cross wire requirements are met directly from coil material of either smooth or ribbed cold drawn/rolled wire or hot rolled wire.
The key characteristic of the Weldplus plant lies in its complete flexibility in changing from one type of mesh to another and from one size of wire to another without requiring any set-up times. The Weldplus automatically changes from one line wire and/or cross wire size to another, from one mesh width to another, from one mesh length to another or from one internal line and/or cross wire pitch size set-up to another; all without requiring any down-time or operator intervention. Any type of mesh panel can be produced with this machine be it standard, special, structural or engineered.

The modularity of the machine means that the plant can be customised to suit the different requirements of clients.
Generally the broad specifications of the Weldplus plant are:
- between 2 and 8 different line wire diameter sizes can be processed automatically;
- between 2 and 5 different cross wire diameter sizes can be processed automatically;
- the line wire diameter range which can be covered is from 4mm to 16mm;
- the cross wire diameter range which can be covered is from 4mm to 12mm;
- the mesh widths which can be handled are from 400mm to 3000mm;
- the mesh lengths which can be handled are from 1000mm upwards;
- the internal line wire pitch size can be anything from 50mm upwards in steps of 50mm;
- the internal cross wire pitch size can be anything from 50mm upwards;
- the machine automatically changes between different mesh types or pitch sizes or wire sizes.

Obviously the Weldplus plant can be coupled to a variety of complimentary accessories and/or evacuation or mesh col-lection systems according to specifc client requirements.

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