Wire Screen Manufacturing System and Method

Abstract

An exemplary embodiment of wire wrap welding system generally includes a headstock; a bed; a bed mounted tailstock linearly moveable in relation to the headstock; a linear induction drive system adapted to move the tailstock; a linear encoder system having a series of position encoders disposed on the bed; a servomotor adapted to rotate a headstock mounted spindle; a welding system positioned on the headstock, a servomotor positioned on the tailstock and adapted to rotate a tailstock mounted spindle; and a control system. An exemplary embodiment of a method for controlling slot openings between wire segments in a wire wrap welding process generally includes controlling movement of a bed mounted tailstock in relation to the rate of rotation of a headstock mounted spindle, utilizing a linear induction drive system, a linear encoder system, and a control system.

We claim: 
     
         1 . A manufacturing system for producing wire wrap screens for pipe comprising:
 a headstock comprising a spindle;   a welding apparatus positioned on said headstock;   a bed;   a tailstock positioned on said bed and comprising a spindle;   a first rotary actuator adapted to provide rotation of said headstock spindle;   a second rotary actuator adapted to provide rotation of said tailstock spindle; and   at least one component selected from the group consisting of:
 a linear induction drive system adapted to provide linear movement of said tailstock in relation to said headstock along said bed; and 
 a linear encoder system adapted to determine the location of said tailstock in relation to said headstock along said bed. 
   
     
     
         2 . The manufacturing system of  claim 1 , wherein said linear induction drive system comprises:
 a motor assembly comprising one or more motors; and   one or more stators positioned on said bed.   
     
     
         3 . The manufacturing system of  claim 1 , wherein said linear induction drive system comprises:
 one or more roller tracks positioned on said bed; and   one or more guide rollers, each guide roller adapted to cooperate with one of said   roller tracks to provide rolling movement of said motor assembly in relation to said headstock along said bed.   
     
     
         4 . The manufacturing system of  claim 1 , wherein:
 said bed comprises one or more guide rails; and   said tailstock comprises one or more races comprising at least one bearing, each race adapted to cooperate with one of said guide rails to provide low-friction movement of said tailstock in relation to said headstock along said bed.   
     
     
         5 . The manufacturing system of  claim 1 , comprising an additional drive system adapted to provide linear movement of said tailstock in relation to said headstock along said bed. 
     
     
         6 . The manufacturing system of  claim 1 , comprising a control system adapted to control at least one said function is selected from the group consisting of:
 rotation of said headstock spindle;   rotation of said tailstock spindle;   linear movement of said tailstock in relation to said headstock along said bed by said linear induction drive system; and   determination of the location of said tailstock in relation to said headstock along said bed by said linear encoder system.   
     
     
         7 . The manufacturing system of  claim 1 , wherein said linear encoder system is adapted to determine the location of said tailstock in relation to said headstock along said bed, based at least in part, on information provided, directly or indirectly thereto, by at least one of one or more position encoders disposed on said bed. 
     
     
         8 . The manufacturing system of  claim 6 , wherein said determination of the location of said tailstock in relation to said headstock along said bed comprises utilizing, at least in part, information provided, directly or indirectly to said control system, by at least one of one or more position encoders disposed on said bed. 
     
     
         9 . A manufacturing system for producing wire wrap screens for pipe comprising:
 a headstock comprising a spindle;   a welding apparatus positioned on said headstock;   a bed;   a tailstock positioned on said bed and comprising a spindle;   a first rotary actuator adapted to provide rotation of said headstock spindle;   a second rotary actuator adapted to provide rotation of said tailstock spindle;   a linear induction drive system comprising:
 a motor assembly comprising one or more motors; 
 one or more stators positioned on said bed; 
 one or more roller tracks positioned on said bed; and 
 one or more guide rollers, each guide roller adapted to cooperate with one of said roller tracks to provide rolling movement of said motor assembly in relation to said headstock along said bed; 
   a linear encoder system comprising one or more position encoders disposed on said bed; and   a control system; wherein:
 said linear induction drive system is adapted to provide linear movement of said tailstock in relation to said headstock along said bed; 
 said linear encoder system is adapted to determine the location of said tailstock in relation to said headstock along said bed; and 
 said control system is adapted to control at least one function of said manufacturing system. 
   
     
     
         10 . The manufacturing system of  claim 9 , wherein:
 said bed comprises one or more guide rails; and   said tailstock comprises one or more races comprising at least one bearing, each race adapted to cooperate with one of said guide rails to provide low-friction movement of said tailstock in relation to said headstock along said bed.   
     
     
         11 . The manufacturing system of  claim 9 , wherein:
 said bed comprises one or more guide rails; and   said tailstock comprises one or more races comprising at least one bearing, each race adapted to cooperate with one of said guide rails to provide low-friction movement of said tailstock in relation to said headstock along said bed.   
     
     
         12 . The manufacturing system of  claim 9 , wherein at least one said function is selected from the group consisting of:
 rotation of said headstock spindle;   rotation of said tailstock spindle;   linear movement of said tailstock in relation to said headstock along said bed by said linear induction drive system; and   determination of the location of said tailstock in relation to said headstock along said bed by said linear encoder system.   
     
     
         13 . The manufacturing system of  claim 9 , comprising an additional drive system adapted to provide linear movement of said tailstock in relation to said headstock along said bed. 
     
     
         14 . A method for controlling the width of slot openings between wire segments in a wire wrapped screen comprising:
 providing a manufacturing system for producing wire wrap screens for pipe; and   operating said manufacturing system to produce said wire wrap screens, wherein said operating comprises utilizing a linear induction drive system to control, at least partially, said width.   
     
     
         15 . The method of  claim 14 , comprising utilizing a linear encoder system to determine the relative location of at least one component of said manufacturing system. 
     
     
         16 . The method of  claim 15 , wherein said manufacturing system comprises:
 a headstock comprising a spindle;   a welding apparatus positioned on said headstock;   a bed;   a tailstock positioned on said bed and comprising a spindle;   a first rotary actuator adapted to provide rotation of said headstock spindle; and   a second rotary actuator adapted to provide rotation of said tailstock spindle;   wherein:
 said linear induction drive system is adapted to provide linear movement of said tailstock in relation to said headstock along said bed; and 
 said linear encoder system is adapted to determine the location of said tailstock in relation to said headstock along said bed. 
   
     
     
         17 . The method of  claim 16 , wherein said manufacturing system comprises at least one component combination selected from the group consisting of:
 one or more roller tracks positioned on said bed, and one or more guide rollers, each guide roller adapted to cooperate with one of said roller tracks to provide rolling movement of a motor assembly comprising said one or more motors in relation to said headstock along said bed; and   one or more guide rails provided on said bed, and one or more races positioned on said tailstock and comprising at least one bearing, each race adapted to cooperate with one of said guide rails to provide low-friction movement of said tailstock in relation to said headstock along said bed.   
     
     
         18 . The method of  claim 16 , wherein said operating a manufacturing system comprises operating a control system to control at least one function selected from the group consisting of:
 linear movement of said tailstock in relation to said headstock along said bed by said linear induction drive system; and   determination of the location of said tailstock in relation to said headstock along said bed by said linear encoder system.   
     
     
         19 . The method of  claim 18 , comprising operating an additional drive system adapted to provide linear movement of said tailstock in relation to said headstock along said bed 
     
     
         20 . The method of  claim 18 , comprising the steps of:
 providing a support for a plurality of ribs;   providing a wire to intersect each said rib;   providing a welding wheel, supported on a support assembly, in contact with said wire at a point of intersection between said wire and one said rib;   rotating said headstock spindle;   moving said tailstock away from said headstock utilizing said linear induction drive system;   welding said wire to said one said rib at said point of intersection;   obtaining measurements, continuously or intermittently, of at least one of the rotation speed of said headstock spindle and the location of said tailstock; and   utilizing said control system to control, based at least in part on said obtained measurements, at least one of:   said first rotary actuator;   said second rotary actuator;   said linear induction drive system and;   said linear encoder system.