Wire Masonry Ladder Machine:Cutter Mechanism & Assembly Build

Chelan Manufacturing, LockRite Metal ProductsOperations ManagerOctober 2013-December 2013Supervisor: Erich Weiler, Owner(425)306-8028

Objective: Design cutting capable of shearing 6 or 9 gauge galvanized or stainless steel wire with

minimal operator adjustment. Use in house supplies and equipment whenever possible Fabricate larger mechanism for holding cutting tool during operation. Install assembly in alignment with existing critical components Modify other components for feeding wire, guiding machine motion, avoiding lines, etc.

Tools/Equipment available: Manual knee mill, variable speed spindle, belt driven MIG Welder with gas Oxy-acetylene cutting torch Friction cut saw Drill press Most common shop hand and air tools

Challenges to overcome: Budget limited to under $300 total material and tooling costs (Set of r8 collets, Kurt vice,

cutters) Management requests often added complexity without increasing overall effectiveness Repairs should be easily performed by operator with little training Use excess inventory for replacing worn-out components Tools and equipment oftentimes required alignment and repair

Bridgeport vertical manual mill used to make many critically dimensioned components for cutter assembly. Required rebuild, alignment, and $100 in tooling costs.

Wire masonry ladder machine. Two 6 or 9 gauge (.148”-.203”) stainless or galvanized steel wire are straightened, while a 3 is cut perpendicular to the other 2 at 6”. A Pneumatic gripper moves

the piece to be spot welded on each side, repeating for each 10’ section.

Cutter mechanism holds 9 gauge galvanized steel wire against carbide tip of lathe tool.

Wire “Ladder” product made in 10’ sections

Cutter mechanism 3d view

Cutter mechanism front view

Cutter mechanism Top view

Cutter mechanism right-side view

Cutter mechanism left-side view, showing 2 gauge possible

Cutter mechanism bottom view

Cutter mechanism assembly with cylinder

Cutter mechanism assembly with pneumatic gripper

Pivot arm used in assembly

Gripper side view, with mechanism

Cutter mechanism assembly, grabber, and spot-welders in place

Machine whole view