Steel reinforcement cage automatic binding system and application thereof

Abstract

The invention relates to an automatic binding system for a reinforcement cage and application of the automatic binding system. The system comprises a control station, a binding jig frame, a four-way rail arranged in the circumferential direction of the binding jig frame, a four-way RGV arranged in a sliding mode in cooperation with the four-way rail, a sub-control piece, a mechanical arm, an identification piece and a binding piece, wherein the sub-control piece and the mechanical arm are arranged on the four-way RGV, and the identification piece and the binding piece are arranged at the output end of the mechanical arm. The control station is in communication connection with the sub-control piece and is used for directly or indirectly controlling the four-way RGV, the mechanical arm, the identification piece and the binding piece; the automatic binding system for the reinforcement cage is applied to binding of the reinforcement cages of T-shaped beams, box beams, pier columns and cover beams. The method has the advantages of improving the production efficiency and ensuring the batch steel bar binding result, and is suitable for batch production of steel bar cages of T beams, box beams, pier columns and cover beams.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of bridge prefabricated component production, in particular to a steel reinforcement cage automatic binding system and application thereof. BACKGROUND

[0002] With the vigorous development of the construction industry, the improvement of construction efficiency has become the focus of the industry. In bridge construction, the beam slab processing link is particularly critical. At present, in order to further improve the construction efficiency, the beam slab processing process has been widely moved to the prefabricated beam field. In this link, the binding operation of the beam slab is still mainly dependent on manual work. The side of the beam slab is distributed with a large number of steel bars that need to be bound, and the steel bar binding currently mainly adopts manual binding and small handheld steel bar binding machines. However, the manual binding method not only consumes time and effort, but also is low in efficiency. Although the small handheld steel bar binding machine can improve the work efficiency to a certain extent, its operation is relatively cumbersome and needs to be held by hand, resulting in huge physical consumption of the operator, so the device is not suitable for widespread use, and the efficiency problem cannot be fundamentally solved. SUMMARY

[0003] In view of the deficiencies of the prior art, the first object of the present application is to provide a steel reinforcement cage automatic binding system, which has the advantages of improving production efficiency and ensuring the batch steel binding result.

[0004] The second object of the present application is to provide an application of a steel reinforcement cage automatic binding system, which has the advantage of being suitable for batch production of steel reinforcement cages of T-beams, box beams, pier columns and bent caps.

[0005] To achieve the above-mentioned first object, the present application provides the following technical solutions: A steel reinforcement cage automatic binding system, comprising a control station, a binding jig, a four-way track arranged around the circumference of the binding jig, a four-way RGV slidingly arranged in cooperation with the four-way track, a sub-control component and a mechanical arm arranged on the four-way RGV, and a recognition component and a binding component arranged at the output end of the mechanical arm, wherein the control station is communicatively connected to the sub-control component and is used to directly or indirectly control the four-way RGV, the mechanical arm, the recognition component and the binding component.

[0006] Further, the binding jig is provided with at least two and is arranged in one-dimensional or two-dimensional array, and a plurality of four-way RGVs are correspondingly provided; the four-way track comprises at least two parallel arranged transverse tracks and a plurality of vertically arranged longitudinal tracks relative to the transverse tracks, and the binding jig is arranged in the grid space formed by the adjacent transverse track and longitudinal track. Wherein, the binding jig can be manually assisted by a positioning component for steel reinforcement cage semi-product loading positioning, or can be positioned by AGV transfer and / or electric drive for steel reinforcement cage semi-product loading positioning.

[0007] Further, the sub-control device is configured to control the moving direction and speed of the four-direction RGV, control the posture of the mechanical arm, control the identification of the identification device, and control the binding of the binding device.

[0008] Further, the identification device is a visual camera, and the binding device is a steel bar binding machine.

[0009] Further, the control process of the system comprises, S1, after the positioning of the steel cage semi-finished product on the binding jig is completed, the position information of the binding jig and the four-direction RGV is configured at the control station, and a binding instruction is sent to the sub-control device, and the four-direction RGV and the mechanical arm form a follow-up relationship; S2, the four-direction RGV moves to the position, the identification device is driven by the mechanical arm to move along the operation surface, the identification scanning is started, the initial binding point is determined as the origin, the binding coordinate system is established, and the binding device completes the binding at the initial binding point; S3, based on the established binding coordinate system, the four-direction RGV and the mechanical arm drive the binding device to move to the remaining binding positions, after the binding device completes the binding of at least one binding point, if there is no next binding position on the operation surface, the next step is performed, otherwise, S2 is repeated; S4, all binding positions are reviewed, the binding quality is checked, if qualified, the binding is completed, the four-direction RGV returns to the control station, and the process ends, otherwise, the welding instruction is modified, and S1 is repeated.

[0010] Further, in the S1, after the sub-control device receives the binding instruction, the moving direction is confirmed, and the binding parameters are obtained, the binding parameters include the operation surface, the starting binding position, the number of binding points, and the theoretical coordinates of the binding points.

[0011] Further, in the S2, based on the binding parameters, the steel image is obtained during the movement of the identification device along the operation surface, image recognition is performed, the distance between the two longitudinally adjacent steel bars, the distance between the two transversely adjacent steel bars, the angle between the transverse steel bar and the vertical direction, and the intersection position are obtained, the relative coordinates of the intersection position are determined, and then the initial binding point is determined. In addition, during the identification scanning process, if the identification device detects that the steel bar layout on the steel cage semi-finished product does not match the preset layout, such as missing steel bars, misplacement or non-conforming spacing, the sub-control device will immediately feed back abnormal information to the control station, and the control station adjusts the binding instruction or issues an alarm according to the feedback to ensure the accuracy and safety of the binding operation.

[0012] Further, in the S2, the steel image includes a front view and other views. Wherein, the identification device performs image fusion on the front view and the other views to improve the accuracy and reliability of the identification, after the initial binding point is determined, the identification device converts the relative coordinates of the initial binding point and the intersection position into absolute coordinates in the binding coordinate system, to provide accurate position information for subsequent binding operations.

[0013] Further, in the S2, after the reinforcement image is preprocessed, the contour is obtained, a plurality of feature maps are obtained based on the contour, the plurality of feature maps are input into a classifier, and the intersection position is determined based on the output of the classifier.

[0014] Further, in the S3, based on the relative coordinates of the intersection position and the theoretical coordinates of the binding point, the binding member forces the reinforcement at the intersection position to move to the binding point, and the binding of the binding point is completed. Specifically, when the two reinforcements are placed at the intersection, the gap between them needs to be controlled to be no more than 15 mm to ensure that the device can smoothly perform the binding operation. If the recognition member detects changes in the position, diameter or material of the reinforcement, the sub-control member will automatically adjust the force and binding method of the binding member to adapt to the characteristics of different reinforcements, ensure that the binding is firm and will not cause damage to the reinforcement, and control the binding tightness and position through an algorithm to avoid problems such as uneven spacing or different tightness caused by manual operation.

[0015] Further, in the S3, the motion path of the four-way RGV and the mechanical arm is planned by the sub-control member according to the absolute coordinates in the binding coordinate system, to ensure that the binding member can accurately reach each binding point. At the same time, the sub-control member also monitors the motion state of the mechanical arm in real time to ensure the stability and accuracy of the binding process.

[0016] Further, in S4, the review process is initiated by the sub-control member, which controls the mechanical arm to drive the recognition member to scan the reinforcement cage again, compares the images before and after binding, and checks whether there are missed or unqualified binding points. If there are unqualified items, the sub-control member will record the abnormal information and feed back to the control station for subsequent processing.

[0017] To achieve the above-mentioned second object, the present application provides the following technical solutions: An application of a reinforcement cage automatic binding system in the reinforcement cage binding of T-beams, box beams, pier columns and bent caps.

[0018] In summary, the beneficial technical effects of the present application are: 1. The system of the present application takes the control station as the core, which is responsible for receiving operation instructions and sending them to the sub-control member. The sub-control member controls the four-way RGV to slide on the four-way track according to the instructions, thereby driving the mechanical arm to move to the specified position. The recognition member arranged on the mechanical arm can accurately identify the shape and intersection position of the reinforcement cage, ensuring that the binding member can accurately bind the reinforcement. 2. The system of the present application also has high flexibility and adaptability, which can be flexibly adjusted according to different construction needs, for example, by adjusting the sliding path of the four-way RGV and the action trajectory of the mechanical arm, the binding of steel cages of different shapes and sizes can be realized, and at the same time, the system can realize automatic control and remote monitoring, further improving the safety and convenience of construction; 3. The system of the present application arranges the cooperation between the binding jig and the four-way RGV through timing, matches the positioning and binding process of the steel cage semi-finished product, not only solves the problem of low efficiency and huge physical consumption of manual binding in the prior art, but also realizes automatic and intelligent binding operation, and finally realizes the review of all binding points through review, ensuring the final batch steel binding result, and providing strong technical support for batch production of bridge precast members. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 is a structural schematic diagram of the steel cage automatic binding system of embodiment 1 of the present application.

[0020] Figure 2 is a connection relationship schematic diagram among the mechanical arm, the identification part, and the binding part of embodiment 1 of the present application.

[0021] Figure 3 is a structural schematic diagram of the binding jig of the T-beam top plate steel cage of embodiment 1 of the present application.

[0022] Figure 4 is a connection relationship schematic diagram among the four-way track, the mechanical arm, the identification part, and the binding part of embodiment 2 of the present application.

[0023] In the figure, 1 is a control station; 2 is a binding jig; 3 is a four-way track; 31 is a transverse moving track; 32 is a longitudinal moving track; 4 is a four-way RGV; 5 is a sub-control part; 6 is a mechanical arm; 7 is an identification part; and 8 is a binding part. DETAILED DESCRIPTION

[0024] In order to make the technical means, creative features, purposes and effects realized by the present application more clear and easy to understand, the present application is further described below in combination with the drawings and specific embodiments.

[0025] Embodiment 1: Refer to Figure 1 and Figure 2 , a steel cage automatic binding system disclosed by the present application, comprising a control station 1, four binding jigs 2 arranged in a two-dimensional array, a four-way track 3 arranged around the circumference of the binding jig 2, three four-way RGVs 4 respectively arranged to slide with the four-way track 3, a sub-control part 5 and a mechanical arm 6 arranged on the four-way RGV 4, and an identification part 7 and a binding part 8 arranged at the output end of the mechanical arm 6.

[0026] The positioning of the steel reinforcement cage semi-finished product can be achieved by the positioning member and manual assistance. Figure 3 The steel reinforcement cage semi-finished product can be positioned by the AGV and the electric drive.

[0027] The four-way track 3 includes at least two parallelly arranged transverse tracks 31 and a plurality of longitudinally arranged longitudinal tracks 32 perpendicular to the transverse tracks 31, and the binding jig 2 is arranged in the grid space formed by the adjacent transverse tracks 31 and longitudinal tracks 32.

[0028] The four-way RGV 4 is a four-way track shuttle vehicle that can move freely in the horizontal and vertical directions. The mechanical arm 6 is generally provided in three sections and can realize six-axis movement. The control block is generally arranged between the four-way RGV 4 and the mechanical arm 6 to control the corresponding movement and realize the interaction between the four-way RGV 4 and the mechanical arm 6.

[0029] The recognition member 7 is a visual camera that is used to collect images within the current visual range of the visual camera and analyze the images by the control block.

[0030] The binding member 8 is a steel reinforcement binding machine that can be controlled by the corresponding control block to realize the binding operation.

[0031] The control station 1 is communicatively connected to the sub-control member 5 and is used to directly or indirectly control the four-way RGV 4, the mechanical arm 6, the recognition member 7, and the binding member 8. The control station 1 and the control block are realized by chips, microprocessors, etc.

[0032] The sub-control member 5 is used to control the movement direction and speed of the four-way RGV 4, the posture of the mechanical arm 6, the recognition of the recognition member 7, and the binding of the binding member 8. The signals exchanged between the sub-control block and the control station 1 include but are not limited to position data, commands, image data, and positioning information, and the communication connection includes but is not limited to wifi, Bluetooth, etc.

[0033] Embodiment 2: Refer to Figure 4 The control process of the steel reinforcement cage automatic binding system disclosed by the present application includes, S1 After the positioning of the steel reinforcement cage semi-finished product on the binding jig 2 is completed, the position information of the binding jig 2 and the four-way RGV 4 is configured in the control station 1, and the binding instruction is initiated to the sub-control member 5. The sub-control member 5 confirms the movement direction and obtains the binding parameters, including the operation surface, the starting binding position, the number of binding points, and the theoretical coordinates of the binding points. The four-way RGV 4 and the mechanical arm 6 form a follow-up relationship. S2 The four-way RGV 4 moves to the position, and the mechanical arm 6 drives the identification member 7 to move along the operation surface to start the identification scanning. Based on the binding parameters, the identification member 7 obtains the steel bar image during the movement along the operation surface, the steel bar image includes the front view and other views, image recognition is performed, after the steel bar image is preprocessed, the contour is obtained, a plurality of feature maps are obtained based on the contour, the plurality of feature maps are input into the classifier, and the spacing between the two longitudinally adjacent steel bars, the spacing between the two transversely adjacent steel bars, the angle between the transverse steel bar and the vertical direction, and the intersection position are determined based on the output of the classifier. The relative coordinates of the intersection position are determined, and the initial binding point is determined. A binding coordinate system is established, and the binding member 8 completes the binding at the initial binding point; In addition, during the identification scanning process, if the identification member 7 detects that the steel bar layout on the steel bar cage semi-finished product does not match the preset layout, such as missing steel bars, misplacement or spacing not meeting the requirements, the sub-control member 5 will immediately feed back abnormal information to the control station 1, and the control station 1 adjusts the binding instruction or issues an alarm according to the feedback to ensure the accuracy and safety of the binding operation; S3 Based on the established binding coordinate system, the movement path of the four-way RGV 4 and the mechanical arm 6 and the posture of the mechanical arm 6 are planned by the sub-control member 5 according to the absolute coordinates in the binding coordinate system, so that the four-way RGV 4 and the mechanical arm 6 drive the binding member 8 to move to the remaining binding positions, and based on the theoretical coordinates of the binding points and the relative coordinates of the intersection positions, the binding member 8 forces the steel bars at the intersection positions to move to the binding points, and completes the binding of the binding points. After the binding member 8 completes the binding of at least one binding point, if there is no next binding position on the operation surface, the next step is performed, otherwise S2 is repeated; Wherein, when the two steel bars are placed in intersection, the gap between them needs to be controlled not to exceed 15mm, to ensure that the equipment can smoothly carry out the binding operation, if the identification member 7 detects the change of the steel bar position, diameter or material, the sub-control member 5 will automatically adjust the strength and binding mode of the binding member 8 to adapt to the characteristics of different steel bars, ensure that the binding is firm and will not cause damage to the steel bars, and control the binding tightness and position through algorithm, avoid the problems such as uneven spacing or different tightness caused by manual operation; S4 The review process is initiated by the sub-control member 5, which controls the mechanical arm 6 to drive the identification member 7 to scan the steel bar cage again, compares the images before and after binding, checks whether there are missed or unqualified binding points, if qualified, the binding is completed, the four-way RGV 4 returns to the control station 1, and the process ends, otherwise, the sub-control member 5 will record the abnormal information and feed it back to the control station 1, modify the welding instruction, and repeat S1.

[0034] Embodiment 3: The application discloses an automatic binding system for a steel bar cage, which is applied to the binding of a steel bar cage for a T-beam, a box beam, a pier column and a bent cap.

[0035] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not limiting. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the purpose and scope of the technical solutions of the present invention, which should all be included in the scope of the claims of the present invention.

Claims

1. An automatic steel cage tying system, characterized by: The invention comprises a control station (1), a tyre tyre lashing frame (2), a four-way track (3) arranged circumferentially around the tyre lashing frame (2), a four-way RGV (4) arranged to slide in cooperation with the four-way track (3), a sub-control component (5) and a mechanical arm (6) arranged on the four-way RGV (4), and an identification component (7) and a tyre lashing component (8) arranged at the output end of the mechanical arm (6); the control station (1) is communicatively connected to the sub-control component (5) and is used to directly or indirectly control the four-way RGV (4), the mechanical arm (6), the identification component (7) and the tyre lashing component (8).

2. The automatic steel cage tying system according to claim 1, characterized in that: The tyre tyre lashing frames (2) are provided with at least two and arranged in a one-dimensional or two-dimensional array, and the four-way RGV (4) is provided with a plurality of corresponding ones; the four-way track (3) includes at least two lateral tracks (31) arranged in parallel, and a plurality of longitudinal tracks (32) arranged perpendicularly to the lateral tracks (31), and the tyre lashing frames (2) are arranged in a grid space formed by adjacent lateral tracks (31) and longitudinal tracks (32).

3. The automatic steel cage tying system according to claim 1, characterized in that: The sub-controller (5) is used to control the movement direction and movement speed of the four-directional RGV (4), control the posture of the mechanical arm (6), control the recognition of the recognition member (7), and control the binding of the binding member (8).

4. The automatic steel cage tying system according to claim 1, characterized in that: The identification component (7) is a visual camera, and the binding component (8) is a steel bar binding machine.

5. The automatic steel cage tying system according to claim 1, characterized in that: The control process of the system includes: After S1 completes the positioning of the semi-finished steel cage on the tying frame (2), it configures the position information of the tying frame (2) and the four-way RGV (4) at the control station (1), and sends a tying instruction to the sub-controller (5), and the four-way RGV (4) and the robotic arm (6) establish a follow-up relationship; S2 The four-way RGV (4) moves to its position, the robotic arm (6) drives the identification member (7) to move along the operating surface, starts the identification scan, determines the initial lashing point as the origin, establishes the lashing coordinate system, and the lashing member (8) completes the lashing at the initial lashing point; In step S3, based on the established lashing coordinate system, the four-way RGV (4) and the robotic arm (6) drive the lashing member (8) to move to the remaining lashing positions. After the lashing member (8) completes the lashing of at least one lashing point, if the next lashing position does not exist on the operating surface, the next step is carried out, otherwise, step S2 is repeated. S4 reviews all the binding positions and checks the binding quality. If qualified, the binding is completed and the four-way RGV (4) returns to the control station (1). Otherwise, the welding instructions are modified and S1 is repeated.

6. The automatic steel cage tying system according to claim 5, characterized in that: In said S1, after receiving the lashing instruction, the sub-controller (5) confirms the movement direction and obtains the lashing parameters, wherein the lashing parameters include the operation surface, the starting lashing position, the number of lashing points, and the theoretical coordinates of the lashing points.

7. The automatic steel cage tying system according to claim 6, characterized in that: In said S2, based on the binding parameters, the identification member (7) obtains the steel bar image during the movement along the operating surface, performs image recognition, obtains the spacing between two adjacent longitudinal steel bars, the spacing between two adjacent transverse steel bars, the angle between the transverse steel bars and the vertical direction, and the intersection position, determines the relative coordinates of the intersection position, and then determines the initial binding point.

8. The automatic steel cage tying system according to claim 7, characterized in that: In said S3, based on the theoretical coordinates of the binding point and the relative coordinates of the intersection position, the binding member (8) forces the steel bars at the intersection position to move to the binding point, and completes the binding of the binding point.

9. The automatic steel cage tying system according to claim 5, characterized in that: In said S3, the motion paths of the four-directional RGV (4) and the robotic arm (6) are planned by the sub-controller (5) according to the absolute coordinates in the lashing coordinate system, ensuring that the lashing member (8) can accurately reach each lashing point.

10. Application of the automatic reinforcement cage tying system according to any one of claims 1 to 9 in tying reinforcement cages of T-beams, box beams, piers, and cap beams.

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