Craftsmanship Unveiled: The "Cost Trap" and "Game-Changing Solution" Hidden in Poultry Cage Floor Wiring
01 Resolving the Conflict Between Load-Bearing and Elasticity
Most commercially available floor wires are made of single hard steels like Q235. While these meet load-bearing requirements, their excessive hardness often causes friction injuries to the birds, leading to footpad dermatitis and breast blisters. Moreover, the lack of cushioning on such hard materials during egg rolling results in persistently high breakage rates.
Dual-Material Structural Upgrade: Combining Rigidity and Flexibility
Chia Tai Electromechanical Enterprise uses Q235 steel as the load-bearing framework of the floor wire to ensure structural stability and support the weight of the flock and eggs. Simultaneously, the main wire strands are replaced with F195 high-roundness specialty wire, which offers greater ductility. This design creates a "micro-vibration" cushioning effect with every interaction between the birds and the floor wire, acting like a soft protective layer that prevents various injuries.
Precise Diameter Control
Typically, wires that are too thick (>4mm) result in excessive hardness, preventing eggs from sinking and cushioning upon impact, thereby directly transmitting force to the eggshell. Wires that are too thin (<2.5mm) lack sufficient yield strength, making the floor wire prone to deformation. Chia Tai Electromechanical Enterprise strictly controls the diameter range (3mm±0.1mm), enabling the floor wire to achieve 2-3mm of elastic deformation under the birds' weight. This converts kinetic energy into elastic potential energy upon egg impact, effectively dissipating force.
Roundness Design: Reducing Warping Risks
Industry-standard wires are typically oval-shaped, making them susceptible to torsion during machine straightening, which leads to localized warping of the floor wire. The high-roundness specialty wire used by Chia Tai Electromechanical Enterprise employs a cold-drawing process to control roundness error within 0.05mm. This significantly reduces blade marks from machine straightening, enhances the adhesion of anti-corrosion coatings, and extends product lifespan by 3-5 years.
02 Medium-Frequency Welding: Eliminating Weld Failures and Spatter
Traditional line-frequency welding processes often result in weld failures and spatter due to unstable heat input. Weld failures refer to uneven weld penetration and loose wire connections, causing eggs to get stuck in gaps and break during rolling or the floor wire to wobble when stepped on. Spatter, like "nails on the floor," refers to sharp protrusions formed by flying weld slag, which not only scratch eggshells or chicken claws but also become starting points for corrosion.
To achieve more consistent product quality, Chia Tai Electromechanical Enterprise adopts a more stable medium-frequency inverter welding process. This kilohertz-level current frequency monitors real-time changes in weld resistance and automatically compensates for current and pressure fluctuations, suppressing spatter and false welding at the source while preventing base material degradation. This process enhances both the mechanical consistency and appearance quality of weld points: wire connections are stronger, surfaces are smooth and free of protrusions, and risks of egg breakage and biological damage are eliminated from the root. This improves the rate of acceptable products and reduces maintenance costs.
03 The Golden Slope: Balancing Efficiency and Welfare
The slope design of the floor wire directly impacts egg collection efficiency and bird health. When the slope is less than 6°, eggs lack sufficient rolling momentum and are prone to滞留 on the floor wire, leading to breakage from trampling. When the slope exceeds 9°, eggs roll too forcefully, increasing the risk of collisions. Moreover, on overly steep slopes, birds experience uneven pressure distribution on their toes while standing, leading to chronic damage to connective tissues and ligaments and further contributing to footpad dermatitis.
To achieve optimal results, Chia Tai Electromechanical Enterprise’s technical team derived an ideal slope of 6.8° based on the biological characteristics of birds and the formula for egg rolling initiation torque.
Biological Characteristics
From a biological perspective, a bird’s standing posture is determined by bone structures such as femoral adduction and tibial inclination. The vertical line of its center of gravity forms a natural angle of 7.2° (±0.5°) with the toe joint. A 6.8° slope aligns well with this biological feature, dispersing pressure on the footpad and effectively reducing the incidence of footpad dermatitis, ensuring healthier and more comfortable living conditions for the birds.
Physics Foundation
From a physics perspective, higher slopes generally impart greater kinetic energy to objects, resulting in stronger impact forces. Through the circular design and elastic micro-deformation of the F195 wire, Chia Tai Electromechanical Enterprise reduces the friction coefficient of the floor wire. This allows eggs to achieve higher rolling efficiency even on gentler slopes while keeping acceleration and impact forces within a reasonable range, avoiding the "defective egg risk" associated with excessively steep slopes.
04 Innovation System Covering the Entire Product Lifecycle
The 6.8° "golden slope" is not accidental but a systematic breakthrough built on the elasticity of F195 high-roundness wire, the reliability of medium-frequency welding, and the precise load-bearing capacity of Q235 steel.
Chia Tai Electromechanical Enterprise’s innovation in cage floor wires essentially replaces traditional empiricism with scientifically quantifiable thinking. By integrating interdisciplinary knowledge of materials mechanics, thermodynamics, and biology, the company addresses the pain points of layer farming with precision.
The sustainability of this innovation system is rooted in a service philosophy centered on "creating value for customers and ensuring customer satisfaction." This innovation ecosystem, which prioritizes customer value and empowers striving individuals, represents the core advantage of Chia Tai Electromechanical Enterprise in the global agricultural and food equipment sector.