Double-block sleeper reinforcement manufacturing and installation system

Abstract

The present invention belongs to the field of automated production of double-block sleepers, and specifically is a double-block sleeper steel bar manufacturing and installation system. It includes a steel bar manufacturing system and a steel bar installation system. The steel bar manufacturing system includes a CNC hoop bending machine, an industrial robot, a grabbing tool, a welding platform, a conveyor belt and an electric welder. The CNC hoop bending machine is independently arranged at one place, the conveyor belt is arranged next to the CNC hoop bending machine, the welding platform is arranged above the end of the conveyor belt, and two industrial robots are arranged and symmetrically arranged on both sides of the conveyor belt, and the other side of the conveyor belt. The steel bar installation system includes a portal bracket, a clamp, a bending hook machine, a truss separation mechanism, a truss steel bar translation frame and a steel bar assembly platform. The portal bracket is arranged on the outside of the steel bar assembly platform, and rails are arranged on both sides of the upper part of the portal bracket. Clamps that can move along the rails are installed on the rails. The steel bar assembly platform is arranged below the portal bracket and connected to the conveyor belt.

Description

Technical Field

[0001] The invention belongs to the field of automatic production of double-block sleepers, in particular to a double-block sleeper reinforcement manufacturing and installation system. Background Art

[0002] The stirrups and truss steel bars required for the prefabrication of double-block sleepers are all made on-site, and then workers manually assemble and install them in molds on site. Traditional manual production of steel bars requires the use of mechanical equipment to bend and shape stirrups and truss steel bars, and then manually weld them into shape. Then, the whole stack of truss steel bars are manually separated, and the stirrups and truss steel bars are placed in the reserved notches in the mold in turn. Finally, the stirrups and truss steel bars are connected together using cold-drawn steel wires, and the truss steel bars are pressed with a pressure plate. This manual + mechanical method has problems such as large personnel input, high labor intensity, long operation time, uncontrollable quality, and slow construction efficiency. On the other hand, manual bending and welding of steel bars poses safety hazards and occupational health hazards, which have a great impact on the health of construction workers. Summary of the invention

[0003] In order to solve the above problems, the present invention provides a double-block sleeper reinforcement manufacturing and installation system.

[0004] The present invention adopts the following technical scheme: a double-block sleeper reinforcement manufacturing and installation system, comprising a reinforcement manufacturing system and a reinforcement installation system.

[0005] The steel bar production system includes a CNC hoop bending machine, an industrial robot, a grabbing tooling, a welding platform, a conveyor belt and an electric welder. The CNC hoop bending machine is independently set at one place, the conveyor belt is arranged next to the CNC hoop bending machine, the welding platform is set above the end of the conveyor belt, and there are two industrial robots that are symmetrically arranged on both sides of the conveyor belt. A grabbing tooling is installed on the end of one of the industrial robots, and an electric welder is installed on the other industrial robot and is set on the other side of the conveyor belt.

[0006] The steel bar installation system includes a portal bracket, a clamp, a hook bending machine, a truss separation mechanism, a truss steel bar translation frame and a steel bar assembly platform. The portal bracket is arranged on the outside of the steel bar assembly platform, and rails are arranged on both sides of the upper part of the portal bracket. Clamps that can move along the rails are installed on the rails. The steel bar assembly platform is arranged under the portal bracket and connected to the conveyor belt; hook bending machines are arranged on both sides of the steel bar assembly platform; the steel bar assembly platform and the truss separation mechanism are staggered, and the two are connected and transported by a truss steel bar translation frame.

[0007] A left groove and a right groove are respectively arranged on both sides of the bottom of the grabbing tooling, a movable groove is arranged between the left groove and the right groove, the end of the movable groove is connected to the cylinder, and the movement of the groove is realized by the extension and contraction of the cylinder.

[0008] The welding platform is tilted, and a pressure plate and a limit stop are arranged on the welding platform. A limit stop is arranged along the upper, lower, left and right sides of the welding platform respectively, wherein the upper, left and right limit stops are fixed on the welding platform, and the lower limit stop is installed on the cylinder.

[0009] The clamp includes a pressure plate rotating device, a steel bar pressing plate, a truss gripper and a steel bar anti-falling top plate. The pressure plate rotating device is installed in the middle of the lower side of the clamp, and the pressure plate rotating device is installed at the inner center of the clamp. The steel bar pressing plate, the truss gripper and the steel bar anti-falling top plate are arranged symmetrically about the center line. The steel bar square falling top plate is connected to the bottom of the clamp through a cylinder, and two side-by-side grooves are arranged at the bottom of the truss gripper.

[0010] The pressing plate rotating device comprises a rotating frame arranged at the center of the bottom of the clamp, two sides of the rotating frame are fixedly connected with the hook frame through a cylinder, and the hook frame is provided with a perforation.

[0011] The truss separation mechanism includes a separation mechanism, a bracket and a lifting cylinder. The lifting cylinder is installed in the middle of the bracket. The lower end of the lifting cylinder is connected to the long plate. The two ends of the long plate are connected to the separation mechanism through the central axis. The upper two sides of the separation mechanism are symmetrically arranged with upright trapezoids, and the lower two sides of the separation mechanism are symmetrically arranged with inverted trapezoids. The ends of the upright trapezoid and the inverted trapezoid are connected to the telescopic cylinder.

[0012] The steel bar assembly platform includes a conveyor belt, a top block and a hook bending machine. The hook bending machines are arranged on both sides of the conveyor belt, the top block is arranged under the conveyor belt, and the lifting cylinder is arranged at the bottom of the top block.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] 1. The present invention has a simple structure, reasonable design, low investment cost, convenient installation and layout, and occupies a small area.

[0015] 2. The present invention is easy to use and operate, and has low operating difficulty.

[0016] 3. The present invention reduces manpower input and reduces labor intensity.

[0017] 4. The present invention simplifies the operation process, increases the operation speed, and reasonably and effectively improves the construction efficiency.

[0018] 5. The present invention solves the problems of insufficient bending length and angle, incomplete welding, insufficient length and burned steel bars caused by manual bending and welding, and ensures the production quality of stirrups and truss steel bars.

[0019] 6. The on-site hook manufacturing of the present invention avoids the situations of missing hooks and skewed stirrups, and eliminates the phenomenon of steel bar film sticking.

[0020] 7. The automatic rotating pressing plate of the present invention limits the position of the steel bars, eliminates the situation of artificial pressure leakage and inadequate pressure, ensures that the position of the steel bars is fixed, and prevents the steel bars from floating and shifting.

[0021] 7. The present invention automatically manufactures and installs steel bars throughout the entire process, accurately controls to reduce potential safety hazards, and eliminates occupational health hazards without human operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 A schematic diagram of stirrup welding provided by the present invention;

[0023] Figure 2 A schematic diagram of a steel bar installation system provided by the present invention;

[0024] Figure 3 A schematic diagram of a steel bar assembly platform provided by the present invention;

[0025] Figure 4 A schematic diagram of the grabbing tooling provided by the present invention;

[0026] Figure 5 A schematic diagram of a welding platform provided by the present invention;

[0027] Figure 6 A schematic diagram of a clamp provided by the present invention;

[0028] Figure 7 It is a schematic diagram of the structure of the truss steel bar translation frame;

[0029] Figure 8 It is a structural schematic diagram of the pressing plate rotating device;

[0030] Fig. 9 is a schematic diagram of the truss separation mechanism;

[0031] Fig.10 It is a partial schematic diagram of the truss separation mechanism;

[0032] In the figure, 1-stirrup; 2-CNC hoop bending machine; 3-industrial robot; 4-grabbing tooling; 4.1-left groove; 4.2-right groove; 4.3-movable groove; 5-electric welding machine; 6-welding platform; 6.1-pressing plate; 6.2-limiting block; 6.3-cylinder; 7-conveyor belt; 8-double-block sleeper mold; 9-gantry bracket; 10-clamp; 11-steel assembly platform; 12-hook bending machine; 13-truss steel bar translation Frame; 14-truss separation mechanism; 14.1-separation mechanism; 14.2-bracket; 14.3-lifting cylinder; 14.4-long board; 14.5-central axis; 14.6-telescopic cylinder; 14.7-upright trapezoid; 14.8-inverted trapezoid; 15-truss reinforcement; 16-pressing plate rotating device; 18-rebar pressing plate; 19-truss gripper; 20-rebar anti-falling top plate; 21-rotating frame; 22-cylinder; 23-hook frame. DETAILED DESCRIPTION

[0033] The present invention will be further described below in conjunction with the accompanying drawings.

[0034] like Figure 1 , Figure 2 , Figure 3 As shown, a dual-block sleeper reinforcement manufacturing and installation system includes a reinforcement manufacturing system and a reinforcement installation system.

[0035] The steel bar production system includes a CNC hoop bending machine 2, an industrial robot 3, a grabbing tool 4, a welding platform 6, a conveyor belt 7 and an electric welder 5. The CNC hoop bending machine 2 is independently set at one place, the conveyor belt 7 is arranged next to the CNC hoop bending machine 2, the welding platform 6 is set above the end of the conveyor belt 7, and there are two industrial robots 3 and they are symmetrically arranged on both sides of the conveyor belt 7. The grabbing tool 4 is installed on the end of one of the industrial robots 3, and the electric welder 5 is installed on the other industrial robot 3 and is set on the other side of the conveyor belt.

[0036] The steel bar installation system includes a portal bracket 9, a clamp 10, a hook bending machine 12, a truss separation mechanism 14, a truss steel bar translation frame 13 and a steel bar assembly platform 11. The portal bracket 9 is arranged on the outside of the steel bar assembly platform 11, and rails are arranged on both sides of the upper part of the portal bracket 9. Clamps 10 that can move along the rails are installed on the rails. The steel bar assembly platform 11 is arranged below the portal bracket 9 and is connected to the conveyor belt 7; hook bending machines are arranged on both sides of the steel bar assembly platform 11; the steel bar assembly platform 11 and the truss separation mechanism 14 are staggered, and the two are connected and transported by a truss steel bar translation frame 13 in the middle.

[0037] The bottom of the grabbing tool 4 is provided with a left groove 4.1 and a right groove 4.2 on both sides, and a movable groove 4.3 is provided between the left groove 4.1 and the right groove 4.2. The end of the movable groove 4.3 is connected to a cylinder, and the movement of the groove is achieved by the extension and contraction of the cylinder. By moving and grabbing the steel bar on one side of the stirrup, the leftmost groove restricts the other side of the stirrup, ensuring that it can be grabbed and placed on the welding platform.

[0038] The welding platform 6 is tilted, and a pressure plate 6.1 and a limit stop 6.2 are provided on the welding platform 6. One limit stop 6.2 is provided along the upper, lower, left and right sides of the welding platform 6, respectively. The upper, left and right limit stops 6.2 are fixed on the welding platform 6, and the lower limit stop 6.2 is installed on the cylinder 6.3.

[0039] The clamp 10 includes a pressure plate rotating device 16, a steel bar pressing plate 18, a truss gripper 19 and a steel bar anti-falling top plate 20. The pressure plate rotating device 16 is installed in the middle of the lower side of the clamp 10, and the pressure plate rotating device 16 is installed at the inner center position of the clamp 10. The steel bar pressing plate 18, the truss gripper 19 and the steel bar anti-falling top plate 20 are arranged symmetrically about the center line. The steel bar anti-falling top plate 20 is connected to the bottom of the clamp 10 through a cylinder, and two grooves arranged side by side are arranged at the bottom of the truss gripper 19.

[0040] The pressure plate rotating device 16 includes a rotating frame 21 arranged at the bottom center of the clamp 10. Both sides of the rotating frame 21 are fixedly connected to a hook frame 23 through a cylinder 22. The hook frame 23 is provided with a through hole.

[0041] The truss separation mechanism 14 comprises a separation mechanism 14.1, a bracket 14.2 and a lifting cylinder 14.3. The lifting cylinder 14.3 is installed in the middle of the bracket 14.2. The lower end of the lifting cylinder 14.3 is connected to a long plate 14.4. Both ends of the long plate 14.4 are connected to the separation mechanism 14.1 through a central axis 14.5. Upright trapezoids 14.7 are symmetrically arranged on both sides of the upper part of the separation mechanism 14.1, and inverted trapezoids 14.8 are symmetrically arranged on both sides of the lower part of the separation mechanism 14.1. The ends of the upright trapezoid 14.7 and the inverted trapezoid 14.8 are connected to the telescopic cylinder 14.6. The lifting action is achieved by a lifting cylinder; the bottom of the truss separation mechanism is a left-right symmetrical structure, the upper part of the end of the separation mechanism is a right trapezoid, and the two sides can be overlapped by the extension and contraction of the cylinder, thereby lifting the upper chord of the truss reinforcement; the lower part of the end of the separation mechanism is an inverted trapezoid, and the lower chord of the truss reinforcement can be lifted by the extension and contraction of the telescopic cylinder, and the truss reinforcement can be flipped and inverted by rotating 180° along the central axis at the end of the separation mechanism.

[0042] The steel bar assembly platform 11 includes a conveyor belt 11.1, a top block 11.2 and a hook bending machine 11.3. The hook bending machines 11.3 are arranged on both sides of the conveyor belt 11.1, the top block 11.2 is arranged below the conveyor belt 11.1, and a lifting cylinder is arranged at the bottom of the top block 11.2. The conveyor belt is used to transport the stirrups to the designated position; the bottom of the top block is connected to the cylinder, and the top block is lifted and lowered by the cylinder extension and contraction, and the stirrups are positioned and lifted after reaching the designated position; the hook bending machine uses low-carbon steel cold-drawn wire to bend the hook connector with hooks at both ends on site, and connects the stirrups and truss steel bars together.

[0043] The working process of the present invention is as follows: After different types of cold-rolled steel bars are discharged, straightened, welded, sheared, and stacked through the truss steel bar CNC production line, a row of truss steel bars are transported to the truss separation mechanism, two truss steel bars are separated by the truss separation mechanism, and then flipped and placed side by side on the truss steel bar translation frame, and the truss steel bars are transported to the front of the steel bar assembly platform. At the same time, the CNC hoop bending machine discharges, straightens, and bends the unclosed stirrups, and the industrial robot equipped with the grabbing tooling grabs the stirrups and places them on the welding platform. The welding platform is shaped by extrusion and limiting, and the industrial robot equipped with the electric welding machine locates the stirrup welding position by setting coordinates to perform carbon dioxide shielded welding. After welding is completed, the welding platform is relaxed to allow the stirrups to slide onto the conveyor belt, and then transported to the designated position of the steel bar assembly platform via the conveyor belt. After the two stirrups reach the designated position, the bracket under the assembly platform rises to raise the stirrups to a certain height. The clamp picks up the two truss steel bars on the truss steel bar translation frame and transports them to the top of the steel bar assembly platform. The hook bending machine uses cold-drawn steel bars to bend hooks on the stirrups and truss steel bars, so that the hooks hook the stirrups and truss steel bars. After the hook bending is completed, the bracket under the assembly platform drops to the original position so that the hooks hook the stirrups and truss steel bars up and down respectively, keeping the stirrups hanging below the truss steel bars. The clamp picks up the assembled steel bars and raises them to a certain height. Through the coordinate position positioning, it is accurately translated to the top of the corresponding inner cavity of the mold cavity. After alignment, the clamp slowly descends to put the steel bars into the reserved groove in the mold cavity. After the clamp relaxes and presses down, the pressure plate rotating device clamps the middle pressure plate of the mold and rotates 90 degrees to make the pressure plate press the truss steel bars firmly. The placement of the steel bars leads to the fabric and vibration, which causes the steel bars to float and fall off. After the mold installation is completed, the clamp returns to the top of the steel bar assembly platform to wait for the next set of steel bars to be assembled and installed. After the inner cavity of the mold is fully installed, the mold enters the next process.

[0044] While the invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the claims.

Claims

1. A double-block sleeper reinforcement manufacturing and installation system, characterized in that: Including steel bar production system and steel bar installation system, The steel bar manufacturing system comprises a CNC hoop bending machine (2), an industrial robot (3), a grabbing tool (4), a welding platform (6), a conveyor belt (7) and an electric welder (5), wherein the CNC hoop bending machine (2) is independently arranged at one location, the conveyor belt (7) is arranged beside the CNC hoop bending machine (2), the welding platform (6) is arranged above the end of the conveyor belt (7), two industrial robots (3) are arranged symmetrically on both sides of the conveyor belt (7), one of the industrial robots (3) is equipped with a grabbing tool (4) at its end, and the other industrial robot (3) is equipped with an electric welder (5) and is arranged on the other side of the conveyor belt; The steel bar installation system comprises a portal support (9), a clamp (10), a hook bending machine (12), a truss separation mechanism (14), a truss steel bar translation frame (13) and a steel bar assembly platform (11); the portal support (9) is arranged outside the steel bar assembly platform (11); rails are arranged on both sides of the upper part of the portal support (9); clamps (10) that can move along the rails are installed on the rails; the steel bar assembly platform (11) is arranged below the portal support (9) and connected to the conveyor belt (7); hook bending machines are arranged on both sides of the steel bar assembly platform (11); the steel bar assembly platform (11) and the truss separation mechanism (14) are staggered, and the two are connected and transported by a truss steel bar translation frame (13) in the middle; The clamp (10) comprises a pressure plate rotating device (16), a steel bar pressing plate (18), a truss gripper (19) and a steel bar anti-falling top plate (20); the pressure plate rotating device (16) is installed in the middle of the lower side of the clamp (10); the pressure plate rotating device (16) is installed at the inner center of the clamp (10); the steel bar pressing plate (18), the truss gripper (19) and the steel bar anti-falling top plate (20) are arranged symmetrically about the center line; the steel bar anti-falling top plate (20) is connected to the bottom of the clamp (10) through a cylinder; and two grooves arranged side by side are arranged at the bottom of the truss gripper (19); The truss separation mechanism (14) comprises a separation mechanism (14.1), a bracket (14.2) and a lifting cylinder (14.3); the lifting cylinder (14.3) is installed in the middle of the bracket (14.2); the lower end of the lifting cylinder (14.3) is connected to the long plate (14.4); the two ends of the long plate (14.4) are connected to the separation mechanism (14.1) through a central axis (14.5); upright trapezoids (14.7) are symmetrically arranged on both sides of the upper part of the separation mechanism (14.1); inverted trapezoids (14.8) are symmetrically arranged on both sides of the lower part of the separation mechanism (14.1); and the ends of the upright trapezoid (14.7) and the inverted trapezoid (14.8) are connected to the telescopic cylinder (14.6); After the cold-rolled steel bars are unloaded, straightened, welded, sheared and stacked through the truss steel bar CNC production line, a row of truss steel bars is transported to the truss separation mechanism. After two truss steel bars are separated by the truss separation mechanism, they are flipped and placed side by side on the truss steel bar translation frame. The truss steel bars are transported to the front of the steel bar assembly platform. At the same time, the CNC hoop bending machine releases, straightens, and bends the unclosed stirrups, which are then grabbed and placed on the welding platform by an industrial robot equipped with a grabbing tool. The welding platform is shaped by extrusion and limiting, and the industrial robot equipped with an electric welder positions the stirrup welding site by setting coordinates for carbon dioxide shielded welding. After welding is completed, the welding platform is relaxed to allow the stirrups to slide onto the conveyor belt, which is then transported to the designated position of the steel bar assembly platform. After the two stirrups arrive at the designated position, the bracket below the assembly platform rises to raise the stirrups to a certain height. The clamp picks up the two truss steel bars on the truss steel bar translation frame and transports them to the top of the steel bar assembly platform. The hook bending machine uses cold-drawn steel bars to bend hooks on the stirrups and truss steel bars so that the hooks hook the stirrups and truss steel bars. After the hook bending is completed, the bracket below the assembly platform drops to its original position so that the hooks hook the stirrups and truss steel bars up and down respectively, keeping the stirrups hanging below the truss steel bars. The clamp picks up the assembled steel bars and raises them to a certain height. Through coordinate positioning, it is accurately translated to the top of the corresponding inner cavity of the mold cavity. After alignment, the clamp slowly descends to place the steel bars into the reserved groove in the mold cavity. After the clamp relaxes and presses down, the pressure plate rotating device clamps the middle pressure plate of the mold and rotates it 90 degrees to make the pressure plate press the truss steel bars firmly to prevent the steel bars from floating up and falling off. After the mold installation is completed, the clamp returns to the top of the steel bar assembly platform to wait for the next group of steel bars to be assembled and installed.

2. The dual-block sleeper reinforcement manufacturing and installation system according to claim 1 is characterized in that: The gripping tool (4) is provided with a left groove (4.1) and a right groove (4.2) on both sides of the bottom thereof, respectively; a movable groove (4.3) is provided between the left groove (4.1) and the right groove (4.2); the end of the movable groove (4.3) is connected to a cylinder, and the movement of the groove is achieved by the extension and contraction of the cylinder.

3. The dual-block sleeper reinforcement manufacturing and installation system according to claim 1 is characterized in that: The welding platform (6) is arranged at an angle, and a pressure plate (6.1) and a limit stopper (6.2) are arranged on the welding platform (6). The limit stopper (6.2) is arranged one at a time along the upper, lower, left and right sides of the welding platform (6), wherein the upper, left and right limit stops (6.2) are fixed on the welding platform (6), and the lower limit stopper (6.2) is mounted on the cylinder (6.3).

4. The dual-block sleeper reinforcement manufacturing and installation system according to claim 1 is characterized in that: The pressure plate rotating device (16) comprises a rotating frame (21) arranged at the bottom center of the clamp (10), and two sides of the rotating frame (21) are fixedly connected to a hook frame (23) through a cylinder (22), and a perforation is provided on the hook frame (23).

5. The dual-block sleeper reinforcement manufacturing and installation system according to claim 1 is characterized in that: The steel bar assembly platform (11) comprises a conveyor belt (11.1), a top block (11.2) and a hook bending machine (11.3); the hook bending machines (11.3) are arranged on both sides of the conveyor belt (11.1); the top block (11.2) is arranged below the conveyor belt (11.1); and a lifting cylinder is arranged at the bottom of the top block (11.2).

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