Chain Link Mesh Making Machine

Authors
Abdul Hanan 2k20-MET-01
Zakria Javed 2k20-MET-05
Shoaib Iqbal 2k20-MET-09
Fouzan Azeem 2k20-MET-25
Supervisor
Engr.Umer-Bin-Nooman
MECHANICAL ENGINEERING DEPARTMENT

NFC Institute of Engineering & Technology, Multan

2020-2024
 Chain Link Mesh Making Machine
Abdul Hanan 2k20-MET-01
Zakria Javed 2k20-MET-05
Shoaib Iqbal 2k20-MET-09
Fouzan Azeem 2k20-MET-25

Internal Examiner Project Coordinator

Name: _________________ Name: ___________________

Signature: _______________ Signature: _______________

Head of Department

Name: __________________

Signature: _______________

MECHANICAL ENGINEERING DEPARTMENT

NFC Institute of Engineering & Technology, Multan

2020
 Contents

ABSTRACT....................................................................................................................................5

CHAPTER NO. 1...........................................................................................................................6

Introduction......................................................................................................................................6

1.2 Components...............................................................................................................................6

1.3 Objective....................................................................................................................................6

CHAPTER NO. 2...........................................................................................................................7

Literature review..............................................................................................................................7

2.1 Machine Components and Operation........................................................................................7

2.2 Advancements in Machine Automation....................................................................................7

2.3 Wire Materials and Mesh Designs.............................................................................................7

2.4 Quality Control and Inspection..................................................................................................8

2.5 Industry Applications and Market Trends.................................................................................8

CHAPTER NO. 3...........................................................................................................................9

3.1 Methodology..............................................................................................................................9

3.1.1 Grinding..................................................................................................................................9

3.1.2 Welding...................................................................................................................................9

3.1.3 Facing...................................................................................................................................10
3.1.4 Turning.................................................................................................................................10

3.2 Working...................................................................................................................................10

3.3 Advantages..............................................................................................................................11

3.4 Disadvantages..........................................................................................................................11

3.5 Applications.............................................................................................................................11

CHAPTER NO. 4.........................................................................................................................12

4.1 Result.......................................................................................................................................12

4.2 Conclusion...............................................................................................................................12

4.3 future scope..............................................................................................................................12

4.3.1 Automation and Robotics.....................................................................................................12

4.3.2 Artificial Intelligence and Machine Learning.......................................................................12

4.3.3 Smart Manufacturing and Industry 4.0 Integration..............................................................13

4.3.4 Material Innovations.............................................................................................................13

4.3.5 Energy Efficiency and Sustainability...................................................................................13

4.3.6 Customization and Flexibility...............................................................................................13

4.3.6 Human-Machine Interaction and User Experience...............................................................13

 Abstract
This report is related to compact sized and cost efficient machine that is simple chain link mesh
making machine. This machine is used to make fence by bending the wire into a zig zag pattern,
which than can be linked manually to form a mesh. Now a days the mesh making machine used
in industry are quite large and very costly, so the aim of this project is eliminate both of the said
problems. The chain link mesh making machine is a vital piece of equipment and a valuable
asset in the manufacturing process of chain link fences, though here are many advanced types of
mesh making machines, but our goal in making this machine was to solve four of the main
problems like cost of manufacturing of mesh making machine, reduce it area of installation,
making it portable and to reduce the electrical consumption of the machine by using a dc motor
which is being operated at 12 volts.
 Chapter No. 1
Introduction
Welded wire mesh is the latest development in land wire product industry. The welded wire,
generally called reinforcing wire, is mostly used in cement concrete work for construction of
buildings, National Highway pavements, runways, dams, airports etc. It is also used for fencing
purposes and for partition walls and as a safety guard in engineering workshops.

Fences can be defined as arrangement that provides an obstruction, enclosure, or a boundary,

made up of posts or stakes linked together by boards, wire, or rails. The chains run vertically and
are bent into a zigzag pattern so that each "zig" hooks with the wire immediately on one side and
each "zag" with the wire immediately on the other. The manufacturing of chain-link fencing is
called weaving.

Preparing zigzag shape wire is a quite challenging task and cannot be done using basic
mechanisms. So here we design a smart mechanism to automatically bend wires in order to get
zigzag shaped wire for mesh. These wires can then be linked together to create chain link or
meshes.

1.2 Components
 DC Motor
 Shaft
 Internal Rod
 Slotted Pipe
 Mesh Wire
 Base Frame
 Bearing

1.3 Objective
 To reduce cost of machine.
 To provide another method of fence/mesh making.
 Portable and lesser area required for installation.
 Chapter No. 2
Literature review
Chain link mesh making machines are essential in the manufacturing process of chain link
fences. These machines automate the production of chain link mesh, improving efficiency and
quality. This literature review aims to explore the advancements, challenges, and applications of
chain link mesh making machines, providing an overview of the existing research in this field.

2.1 Machine Components and Operation

The chain link mesh making machine consists of several components, including wire pay-off
systems, wire straightening units, wire feeding mechanisms, weaving heads, and fence fabric
winding systems. Researchers have focused on improving the efficiency and reliability of each
component. Studies have explored the use of advanced sensors, servo systems, and control
algorithms to enhance the precision and speed of wire feeding and weaving processes.

2.2 Advancements in Machine Automation

Automation plays a crucial role in chain link mesh making machines. Researchers have
investigated the integration of computer numerical control (CNC) systems, programmable logic
controllers (PLCs), and human-machine interfaces (HMIs) to automate various machine
functions. These advancements enable operators to program and control the machine with ease,
reducing the chances of errors and improving overall productivity.

2.3 Wire Materials and Mesh Designs

Chain link fences are produced using different types of wires, including galvanized steel,
stainless steel, and PVC-coated wires. The choice of wire material influences the durability and
applications of the resulting chain link mesh. Researchers have explored the impact of wire
characteristics, such as diameter, tensile strength, and coating, on the performance of chain link
fences. Additionally, studies have focused on optimizing mesh designs, considering factors like
mesh size, gauge, and height, to meet specific requirements.
2.4 Quality Control and Inspection
Maintaining consistent quality is essential in chain link mesh production. Researchers have
investigated non-destructive testing methods, such as vision systems and laser sensors, to detect
defects and ensure the accuracy of mesh dimensions. Automated inspection systems integrated
into the machine enable real-time monitoring and reject faulty products, minimizing waste and
increasing product quality.

2.5 Industry Applications and Market Trends

Chain link fences find applications in various industries, including agriculture, construction, and
security. Researchers have explored the specific requirements and challenges faced by these
industries, leading to the development of specialized chain link mesh making machines. The
market for chain link mesh making machines is expanding globally, driven by infrastructure
development and increased demand for security solutions. Into the machine enable real-time
monitoring and reject faulty products, minimizing waste and increasing product quality.
 Chapter No. 3
3.1 Methodology
First select the 4mm thick metal plate for base so that the base is heavy, stable and less vibrations
are produced. Mark and weld the supports needed to hold the slotted pipe, bearing and the motor.
Weld internal rod to the bearing, then mount the bearing on one end of the shaft connected to the
motor. Insert the rod in the slotted pipe in which it will rotate. When the power is given to the
motor it turns the shaft which in turn rotates the rod inside the slotted pipe, when the wire is fed
to the machine via slots cut on pipe the wire is bent into zig zag pattern.

3.1.1 Grinding
First of all, we procure the material then we perform grinding function to clean its surface and
bring the material to its required dimensions and shape. Then we used portable grinder to cut
slots in the pipe.

3.1.2 Welding
We weld the supports required to uphold the pipe, motor and the bearing, we also welded the
internal rod to the bearing which was mounted over one end of the shaft of the dc motor.
3.1.3 Facing
We perform the facing process on the shaft to bring it to required length.

3.1.4 Turning
We perform the turning process on a shaft of the dc motor to bring to its required length.

3.2 Working
This system we make use of a wire bobbin to supply raw wire to the system, a DC motor with
shaft connected to a unique mechanism that achieves our bending requirements. The system is a
small yet complex system that achieves the task with ease.
When the DC geared motor is powered it rotates thus rotating the rectangular rod attached to its
shaft. Now this rectangular rod is fixed to rotate inside a hollow round tube. Milling operation is
performed on this tube to achieve a spiral shaped cut out on this hollow tube.
So Now as the rectangular rod rotates inside this hollow tube. We now take the wire end from
the bobbin and hook it on the inside rod through the hollow tube slot. We now turn on the
machine. As the motor runs, the rod turns inside the hollow tube. As the hollow tube is cut out in
a spiral shape, the wire moves with the rod spiraling around it and moving outwards.
So now we get a zig zag shaped wire coming out of the other end. Thus the system provides a
fast and easy way to develop zigzag wires for chain link or mesh making.
3.3 Advantages
 Cost efficient.
 Less electricity consumption.
 Portable.
 Easy to use.
 Operator does not need to be trained or technically educated.

3.4 Disadvantages
 Cannot work at high speed
 Bent wire has to be linked manually

3.5 Applications
 Chain link fences are used for perimeter fencing of residential, commercial and industrial
properties.
 The chain link mesh is used for enclosing sports facilities like tennis courts and other
recreational areas.
 These meshes are employed to create secure enclosures for pets, livestock and zoo
animal.
 Chain link mesh serves as a temporary barrier around construction sites to enhance safety
and security.
 Chapter No. 4
4.1 Result
It is a successfully fabricated project. This machine is very useful for small scale applications, it
is cost effective, compact and portable. The working mechanism and fabrication of this machine
is not complicated.

4.2 Conclusion
The chain link mesh making machine is a valuable manufacturing tool that automates the
production of chain link fences. Its cost efficiency and versatility makes it suitable for a wide
range of applications. By streamlining the manufacturing process, this machine contributes to the
rapid and cost rapid production of chain link mesh. This literature on chain link wire mesh
making machine highlights significant progress in automation, process optimization and material
selection. However, there are some issues regarding machine design and improving machine
performance in manufacturing process which are to be addressed and focused upon in the future.

4.3 future scope

The future scope of chain link wire mesh making machines is promising, with potential
advancements in various areas. Here are some key aspects that hold potential for future
developments:

4.3.1 Automation and Robotics

As technology continues to advance, chain link wire mesh making machines can further integrate
automation and robotics. Advanced robotic systems can enhance the speed and precision of wire
feeding, weaving, and other manufacturing processes. Additionally, collaborative robots can
work alongside human operators, improving efficiency and safety in the production environment.

4.3.2 Artificial Intelligence and Machine Learning

Implementing artificial intelligence (AI) and machine learning (ML) algorithms can optimize
machine performance and enhance quality control. AI can be used to analyze real-time data from
sensors and cameras to detect defects, predict machine failures, and optimize production
parameters. ML algorithms can also optimize the machine's energy consumption, material
utilization, and production scheduling, leading to increased efficiency and reduced costs.
4.3.3 Smart Manufacturing and Industry 4.0 Integration
The concept of smart manufacturing and Industry 4.0 focuses on the integration of digital
technologies and data-driven processes. Chain link wire mesh making machines can leverage this
integration by incorporating connectivity, data analytics, and real-time monitoring. This allows
for remote monitoring, predictive maintenance, and improved production planning and
scheduling.

4.3.4 Material Innovations

Research and development efforts can focus on developing new materials for chain link wire
mesh production. This includes exploring alternative wire materials with improved strength,
corrosion resistance, and sustainability. Materials with enhanced properties can lead to more
durable and longer-lasting chain link fences.

4.3.5 Energy Efficiency and Sustainability

The future scope of chain link wire mesh making machines should also consider energy
efficiency and sustainability. Efforts can be directed towards reducing energy consumption
through optimized machine design, motor efficiency, and energy recovery systems. Additionally,
incorporating sustainable manufacturing practices, such as using recycled materials and reducing
waste generation, can contribute to environmental sustainability.

4.3.6 Customization and Flexibility

There is an increasing demand for customized chain link wire mesh products to meet specific
requirements. Future machines can be designed to offer greater flexibility, allowing for easy
customization of mesh sizes, wire materials, and fence designs. This adaptability will enable
manufacturers to cater to a wide range of applications and customer needs.

4.3.6 Human-Machine Interaction and User Experience

The user interface and experience of chain link wire mesh making machines can be improved to
enhance operator productivity and ease of use. Intuitive control interfaces, augmented reality
(AR) guidance, and virtual simulations can facilitate operator training, troubleshooting, and
machine setup.