A method and system for rolling and pipe fitting of reinforcement cage in coordination with rhythm

Abstract

This invention discloses a method and system for coordinated cycle processing of reinforcing cages using a rolling and threading mechanism, belonging to the technical field of reinforcing cage fabrication for bored piles. The method involves arranging sleeve pulley nodes at 2-meter intervals along the axial direction of the reinforcing cage, with the top surfaces of the nodes collinear and forming a shared cycle benchmark. Through a dual-state switching of "rolling-locking," the main reinforcement and sonic logging pipes are threaded with low resistance in the rolling state, while the stirrups are welded in the locked state, achieving parallel threading and welding in the same space. All node components are fabricated on-site using reinforcing steel and standard sleeves, and are 100% recyclable after removal. This invention eliminates the need for external power, transforming traditional sequential processes into parallel cycle operations, significantly shortening the processing cycle, reducing construction costs, and making it suitable for rapid, green, and standardized on-site production of reinforcing cages.

Description

Technical Field

[0001] This invention relates to the field of drilled cast-in-place pile reinforcement cage processing technology, and in particular to a method and system for coordinated cycle processing of reinforcement cages through rolling and pipe insertion. Background Technology

[0002] With the expansion of high-rise buildings and transportation hubs, the number of bored piles has surged, leading to tight construction schedules. Traditional rebar cage fabrication, using fixed frames or thread rolling machines, has the following drawbacks: 1. The main bars of the steel cage have a large diameter and heavy weight, making manual rotation difficult and requiring frequent use of hoisting equipment, resulting in low efficiency and high risk. 2. The lack of drag reduction guidance during the installation of sonic logging pipes often leads to jamming, and long-distance installation requires the cooperation of multiple people, becoming a bottleneck in the progress. 3. The support system is mostly fixed, which makes it impossible to achieve parallel "installation-welding" in the same space. The sequential process results in low shift utilization. 4. There is no unified concept of cycle time for nodes, and the processing time fluctuates greatly depending on the operator's experience, making it difficult to standardize the quality.

[0003] Although existing technologies have proposed rolling brackets and sleeve pulley structures, they have not solved the problems of "how to make the rolling and threading processes run in parallel in time and space" and "quantitative drag reduction under zero power conditions", and still cannot meet the needs of rapid and standardized production. Summary of the Invention

[0004] This invention aims to overcome the shortcomings of existing technologies, such as difficulty in rotating the rebar cage, high resistance in inserting the sonic logging pipe, and low efficiency due to sequential processes. It provides a rebar cage tumbling and pipe insertion coordinated cycle processing method and system. Without increasing external power, the tumbling and insertion are coordinated through the sleeve pulley node, and the node state is switched according to the equal cycle rule, so that the insertion and welding can be carried out in parallel in the same space, thereby reducing the intensity of manual labor, improving processing efficiency, and the node components can be reused.

[0005] To achieve the above objectives, the present invention is implemented as follows: A method for coordinated cycle processing of steel cage rolling and pipe threading includes: a) Arrange several sleeve pulley nodes at equal intervals along the axial direction of the steel cage, with the top surfaces of each node being collinear and forming a shared cycle reference. b) Set the node to a dual state of "rolling" and "locked": - Tumbling state: There is rolling friction between the sleeve pulley and the steel cage, which allows the cage to rotate and slide axially; - Locked state: The sleeve pulley and the steel cage are in rigid contact, which restricts the rotation and sliding of the cage; c) Complete the axial installation of the main reinforcement and sonic logging tubes while the tubes are in a rolling state; d) Complete the welding of the stirrups and main reinforcement bars while the system is locked; e) Switch node states alternately according to a fixed rhythm so that the threading process and the welding process run in the same space.

[0006] Furthermore, the equal spacing is 2 m, which is consistent with the conventional spacing of the reinforcing bars and positioning bars in the steel cage; thus, the existing rib positions can be directly used as the cycle benchmark, eliminating the need for additional measurement and layout time.

[0007] Furthermore, node state switching is achieved by inserting or removing cotter pins, with a switching time of ≤10 s; thus, the rhythm of each beat is controllable, avoiding process waiting.

[0008] Furthermore, the inner diameter of the sleeve pulley is 2-4 mm larger than the outer diameter of the support steel bar, and it is coated with a lubricating medium to ensure that the rolling friction coefficient is always lower than the static friction threshold and maintain a low-resistance rolling state.

[0009] Furthermore, the installation process can be completed by ≤2 people without the need for external power; thus, it meets the zero-power requirements on site, reducing reliance on machinery and construction costs.

[0010] Furthermore, all node components are made from on-site steel bars and standard sleeves, which can be reused; in this way, the cycle resources are recycled, reducing one-time investment and waste generation.

[0011] The present invention also proposes a rebar cage rolling and pipe-threading coordinated cycle processing system for implementing the above method, comprising: a sleeve pulley node module, a connecting rod and a base; the connecting rod keeps the top surfaces of the nodes collinear, and the base is fixed by anchors or counterweights; the system ensures the coordinated accuracy of rolling and welding by preventing node slippage during the cycle advancement.

[0012] This invention transforms the traditional sequential "installation followed by welding" process into parallel operations within the same space by switching between "rolling-locking" dual-state nodes at equal intervals. This significantly shortens the processing time per cage, and all operations can be completed without the need for additional motors or hydraulic equipment on-site. Furthermore, all node components are fabricated using on-site steel reinforcement and standard sleeves, allowing for 100% recycling and direct reuse in the next steel cage after dismantling. This achieves material recycling, reduces construction costs and waste emissions, and meets the requirements of green construction. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the overall layout of the processing system involved in this invention.

[0014] Figure 2 This is an isometric view of the rolling support of the processing system involved in this invention.

[0015] Figure 3 This is a cross-sectional view of the rolling support of the processing system involved in this invention.

[0016] Figure 4 This is a cross-sectional view of the fixed support of the processing system involved in this invention. Detailed Implementation

[0017] The following is in conjunction with the appendix Figures 1-4 This demonstrates how the present invention achieves tumbling-tube-threading coordinated cycle processing in a "zero-power" state.

[0018] Example 1 (Standard 20 m pile cage) 1. Node creation a) Scrolling nodes: such as Figure 2 As shown, two Φ25 threaded steel bars are bent into equilateral triangles with a side length of 0.4 m. The two triangles are welded together with Φ20 steel bars to form a 1 m long frame. A Φ32×60 mm connecting sleeve is placed on the top horizontal bar. The inner diameter of the sleeve is 3 mm larger than the outer diameter of the horizontal bar, allowing it to rotate freely and forming a pulley. A Φ8 mm through hole is pre-drilled at one end of the sleeve for inserting a cotter pin to achieve locking.

[0019] b) Fixed nodes: such as Figure 4 As shown, Φ25 steel bars are welded into 0.4 m equilateral triangles with a spacing of 2 m, and Φ16 threaded steel bars are used in the middle to connect them in a "bench-like" manner; the center of the top horizontal bar is bent to form a 30 mm deep limiting groove, and the groove width is 2 mm larger than the diameter of the main bar to ensure that there is no shaking in the locked state.

[0020] 2. Site setup like Figure 1 As shown, lay out lines on the hardened ground at 2 m intervals. First, place the fixed nodes, then alternately place the rolling nodes. Pull the line to ensure that the top surfaces of all nodes are collinear and the height difference is ≤2 mm. The node bases are tightened with M16 expansion bolts or sandbags on site to prevent slippage.

[0021] 3. Reinforcing cage in place Use a crane or manual labor to lift the semi-finished cage onto the node, so that the main reinforcement falls into the rolling node sleeve and the fixed node limiting groove; at this time, all nodes are in a rolling state, and the cage can be turned by one hand.

[0022] 4. Rhythmic operation a) Installation process: Keep all nodes in a rolling state, apply water-based release agent to the sleeve surface; push the main reinforcement or sonic logging pipe in from one end, and use pulleys to guide the long-distance installation.

[0023] b) Welding process: Insert the cotter pin into the corresponding section of the rolling node, switch to the locked state, and form a rigid workbench; the worker welds around the cage, and after welding 1-2 stirrups, pull out the cotter pin, restore the rolling state, push the cage to rotate to the next welding surface, and repeat the locking-welding-releasing cycle.

[0024] 5. Node recycling After processing, all cotter pins are removed, the steel cage is taken off, the node modules are left in place, and the next cage is directly hoisted down, achieving "zero assembly" turnover.

[0025] Example 2 (Multi-cage parallel operation) When space permits, two sets of node systems can be arranged side by side to form a dual-station production line; while one set is in the threading cycle, the other is in the welding cycle, so that personnel do not interfere with each other and further improve production capacity.

[0026] Example 3 (Extremely Cold Regions) When the ambient temperature is below -5℃, add low-temperature grease to the sleeve to prevent freezing and jamming; replace the base anchors with chemical anchors to ensure reliable anchoring on frozen ground.

[0027] Through the above steps, this invention achieves coordinated rhythmic processing of steel cage rolling and threading without adding any external power, and the node components are 100% recyclable, meeting the requirements of green construction.

[0028] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for coordinated cycle processing of steel cage rolling and pipe threading, characterized in that: include: a) Arrange several sleeve pulley nodes at equal intervals along the axial direction of the steel cage, with the top surfaces of each node being collinear and forming a shared cycle reference. b) Set the node to a dual state of "rolling" and "locked": Tumbling state: There is rolling friction between the sleeve pulley and the steel cage, which allows the cage to rotate and slide axially. Locked state: The sleeve pulley and the steel cage are in rigid contact, restricting the rotation and sliding of the cage; c) Complete the axial installation of the main reinforcement and sonic logging tubes while the tubes are in a rolling state; d) Complete the welding of the stirrups and main reinforcement bars while the system is locked; e) Switch node states alternately according to a fixed rhythm so that the threading process and the welding process run in the same space.

2. The method for coordinated cycle processing of steel cage rolling and pipe threading according to claim 1, characterized in that: The equal spacing is 2 m, which is consistent with the conventional spacing of the reinforcing bars and positioning bars in the steel cage.

3. The method for coordinated cycle processing of steel cage rolling and pipe threading according to claim 1 or 2, characterized in that: Node state switching is achieved by inserting or removing the cotter pin, with a switching time of ≤10 s.

4. The method for coordinated cycle processing of steel cage rolling and pipe threading according to claim 1, characterized in that: The inner diameter of the sleeve pulley is 2-4 mm larger than the outer diameter of the support steel bar, and it is coated with a lubricating medium.

5. The method for coordinated cycle processing of steel cage rolling and pipe threading according to claim 1, characterized in that: The installation process can be completed by ≤2 people and requires no external power.

6. The method for coordinated cycle processing of steel cage rolling and pipe threading according to claim 1, characterized in that: All node components are made of on-site steel bars and standard sleeves, and can be reused.

7. A rebar cage rolling and pipe-threading coordinated cycle processing system for implementing the method of any one of claims 1-6, characterized in that: include: The sleeve pulley node module has a triangular bracket and a rotatable sleeve, and can switch between two states; Connecting rods are used to keep the top surfaces of the nodes collinear and to transmit thrust; The base can be anchored or weighted to the ground to prevent the nodes from slipping.

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