Manufacturing Process of Mesh Cable Tray Climbing Bend

A mesh cable tray climbing bend is manufactured by cutting, welding, and bending wire mesh panels into the desired angled configuration using automated or semi-automated machinery.

Material Selection

The process begins with high-quality steel or stainless steel wires, chosen based on environmental conditions such as indoor or outdoor use. Common finishes include galvanized steel, hot-dip galvanizing, or powder coating to enhance corrosion resistance and durability.

Wire Mesh Fabrication

Linear and horizontal wire feeding: Straight wires are fed into a welding system using a servo-controlled feeding trolley, while horizontal wires are positioned in a blanking system for precise placement. Automatic welding: Welding electrodes, controlled by cylinders, join the wires at intersections to form a rigid mesh panel. Two panels can be welded simultaneously for efficiency.

Mesh forming: The welded mesh is shaped into a flat cable tray panel, ensuring uniform grid spacing and structural integrity.

Cutting and Shaping

Cutting to size: Panels are cut using laser cutting machines, shearing tools, or bolt cutters for on-site adjustments. Protective zinc layers or rubber caps are applied to cut ends to prevent corrosion and ensure safety. Secondary bending: The flat mesh panel is placed in a bending system or press brake to form the climbing bend.

This involves precise angular bends to allow the tray to ascend or descend along a structure while maintaining cable support.

Assembly and Finishing

Edge treatment: Smooth welding seams and protective coatings prevent cable damage during installation. Quality checks: Dimensions, bend angles, and weld strength are verified against design specifications to ensure compliance with load-bearing and safety standards. Optional surface treatment: Additional galvanization or powder coating may be applied to enhance corrosion resistance, especially for outdoor or industrial environments.

Machinery Involved

Roll forming machines: Shape metal strips into tray profiles. Automated welding machines: Ensure precise and fast mesh welding. Press brakes or bending systems: Form complex bends like climbing bends.

Cutting tools: Laser cutters, shears, or bolt cutters for panel sizing.

Summary

The manufacturing of a mesh cable tray climbing bend involves material selection, wire mesh welding, precise cutting, bending into the climbing configuration, and surface finishing. Automation improves accuracy, speed, and consistency, while protective coatings and quality checks ensure durability and safety in electrical installations.