A steel cage processing production line and production method for shield segments

Abstract

The present invention provides a production line and a production method for a steel cage for a shield segment. The steel cage processing line for a shield segment includes a cutting unit, an arc bending unit, a stirrup making unit, a cage body welding unit, an accessory welding unit and a finished product transport unit. The cutting unit and the arc bending unit are connected for material conveying, the accessory welding unit and the finished product transport unit are connected for material conveying, the arc bending unit and the stirrup making unit are arranged side by side on one side of the cage body welding unit, and the accessory welding unit and the finished product transport unit are arranged side by side on the other side of the cage body welding unit; the cage body welding unit includes a U-shaped track and a tire mold frame, and the tire mold frame can carry out cyclic material connection between the arc bending unit, the stirrup making unit and the accessory welding unit; the production method includes seven processing stations, and the tire mold frame can cyclically move back and forth between five of the stations to gradually assemble the steel cage. The present invention has the characteristics of high production efficiency, less configuration personnel, and high automation level.

Description

Technical Field

[0001] The invention relates to the technical field of tunnel equipment, and in particular to a steel cage processing production line and a production method for shield segments. Background Art

[0002] The shield segment is the main assembly component of the shield construction and the outermost barrier of the tunnel. It is responsible for resisting soil pressure, groundwater pressure and some special loads. The quality of the shield segment is directly related to the overall quality and safety of the tunnel, and affects the waterproof performance and durability of the tunnel. The types of shield segments mainly include reinforced concrete segments, steel fiber concrete segments, steel segments, cast iron segments and composite segments. The processing flow of the steel cage in the reinforced concrete shield segment is as follows: the steel bars are cut by a fully automatic shearing machine or a hydraulic cutting machine, and manpower cooperates with a gantry crane to bend the cut steel bars into arcs, and the bent arc-shaped steel bars are stored in the semi-finished product storage rack; manpower cooperates with a gantry crane to lift the semi-finished products from the storage rack to the welding area storage rack for standby; the welding station in the welding workshop uses a fixed steel membrane rack, and the welder installs the stirrups, bottom bars, and surface bars on the membrane rack in turn and welds them; after the steel skeleton is welded into a whole, the skeleton is moved away from the membrane rack, turned 90 degrees and placed upright, and the welding of the connecting bars and the mortise and tenon steel bars begins. After the welding is completed, manpower cooperates with a gantry crane to lift the steel cage to the finished product storage area for standby.

[0003] The applicant has found that the prior art has at least the following technical problems:

[0004] In the existing traditional processing production line, the membrane rack is fixed and cannot be moved. The welding worker needs to complete the threading and welding of a steel cage alone, which requires high comprehensive quality of the welding worker. The steel bars need to be transported three times from raw material processing to semi-finished product storage rack to welding station rack, which wastes a lot of manpower, machinery, electricity and time. The automation level of the production process is low and does not meet the requirements of modern production. The storage rack takes up a large space, and various types of steel bars need to be made in advance. The civilized construction appearance is poor. The welding worker needs to play the triple roles of laborer, welder and gantry operator. The workload is large and the professional division of labor is unclear. Summary of the invention

[0005] The purpose of the present invention is to provide a steel cage processing production line and a production method for shield segments, so as to solve the technical problems existing in the prior art that the automation level of the processing and production process is low and does not meet the requirements of modern production.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] The present invention provides a steel cage processing production line for shield segments, comprising a cutting unit, an arc bending unit, a stirrup making unit, a cage body welding unit, an accessory welding unit and a finished product transportation unit, wherein the cutting unit and the arc bending unit are connected for material conveying, the accessory welding unit and the finished product transportation unit are connected for material conveying, the arc bending unit and the stirrup making unit are arranged side by side on one side of the cage body welding unit, and the accessory welding unit and the finished product transportation unit are arranged side by side on the other side of the cage body welding unit; the cage body welding unit comprises a U-shaped track and a tire mold frame trolley, and the tire mold frame trolley can perform cyclic material connection between the arc bending unit, the stirrup making unit and the accessory welding unit.

[0008] Based on the above technical solution, the present invention can also be improved as follows.

[0009] As a further improvement of the present invention, the bending unit includes a surface rib bending unit and a bottom rib bending unit arranged side by side, and the surface rib bending unit and the bottom rib bending unit are both connected to the cage body welding unit material conveying through a transfer device.

[0010] As a further improvement of the present invention, the cage body assembly welding unit includes a U-shaped track, a tire mold frame trolley movably arranged on the U-shaped track, and a stirrup installation station, a bottom reinforcement installation station, a surface reinforcement installation station, a first welding station and a second welding station arranged at intervals along the U-shaped track, and the stirrup installation station, the bottom reinforcement installation station, the surface reinforcement installation station, the first welding station and the second welding station are respectively arranged corresponding to the stirrup production unit, the bottom reinforcement bending unit, the surface reinforcement bending unit, the top and bottom reinforcement storage unit and the auxiliary steel bar storage unit, and the tire mold frame trolley circulates between the various stations.

[0011] As a further improvement of the present invention, the U-shaped track includes a translation track and a vertical movement track separated from each other, and a ferry car is arranged on the vertical movement track. When the tire mold frame car moves to the two ends of one translation track, the tire mold frame car can be transferred to another translation track by the ferry car.

[0012] As a further improvement of the present invention, the surface rib bending unit and the bottom rib bending unit each include two sets of bending machines, and the number of the transfer devices is four sets, two in a group, and are respectively arranged between the two sets of the bending machines.

[0013] As a further improvement of the present invention, the transfer device includes a transfer track, a transfer vehicle, a reinforcement frame and a pushing assembly, the transfer track is perpendicular to the U-shaped track, the transfer vehicle is slidably arranged on the transfer track, the reinforcement frame is arranged on the transfer vehicle, and the pushing assembly is arranged on the reinforcement frame.

[0014] As a further improvement of the present invention, the tire mold frame vehicle comprises a tire mold vehicle and a mold frame, the tire mold vehicle is slidably arranged on the U-shaped track, and the mold frame is arranged on the tire mold vehicle.

[0015] As a further improvement of the present invention, the accessory assembly welding unit includes a connecting rib welding station and a mortise and tenon welding station arranged side by side, the connecting rib welding station is connected to the second welding station and the mortise and tenon welding station through a gantry crane, and the finished product transportation unit is connected to the mortise and tenon welding station through a gantry crane.

[0016] As a further improvement of the present invention, it also includes a control module electrically connected to the tire mold frame vehicle, and the tire mold frame vehicle can be driven by the control module to move circularly on the U-shaped track.

[0017] As a further improvement of the present invention, the number of the tire mold racks is at least 2.

[0018] The present invention provides a production method for producing a steel cage using the steel cage processing line for shield segments. The steel cage production process is completed in the following seven stations in sequence:

[0019] Step 100, stirrup installation station: the CNC stirrup bending machine is used to make the stirrups required for the steel cage, and after the tire formwork frame vehicle is positioned at the stirrup installation station, the positioned stirrups are manually installed on the tire formwork frame vehicle, and the tire formwork frame vehicle moves to the next station, the bottom reinforcement installation station;

[0020] Step 200: Bottom reinforcement installation station: the steel bars cut by the fully automatic shearing machine are transferred to the storage rack of the fully automatic bending machine, and the storage rack is automatically loaded; after the bottom reinforcement is bent and formed, it is placed on the reinforcement frame in the transfer device, and the pushing component at the bottom of the reinforcement frame is used to push the bottom reinforcement into the mold frame of the tire mold frame vehicle; the bottom reinforcement in the mold frame is manually placed, and the tire mold frame vehicle moves along the track to the next station, the surface reinforcement installation station;

[0021] Step 300: Gluten installation station: The steel bars cut by the fully automatic shearing machine are transferred to the material storage rack of the fully automatic bending machine, and the material storage rack is automatically loaded; after the gluten is bent and formed, it is placed on the rib frame of the transfer device, and the pushing component at the bottom of the triangular rib frame on the transfer vehicle is used to push the gluten into the mold frame of the tire mold frame vehicle; the gluten in the mold frame is manually placed, and the tire mold frame vehicle moves to the next station, the first welding station;

[0022] Step 400: First welding station: sequentially perform connection welding of bottom reinforcement and surface reinforcement, connection welding of bottom reinforcement and stirrup, connection welding of surface reinforcement and stirrup. When installing the bottom reinforcement and surface reinforcement at the bottom reinforcement welding station and the surface reinforcement welding station, spot welding will be performed for preliminary fixation. The tire mold drives to the next station, the second welding station;

[0023] Step 500: Second welding station: perform all welding except for the connecting bars and the concave and convex tenon steel bars to form the skeleton steel bars; after welding, manually cooperate with the gantry crane to lift the skeleton steel bars away from the formwork and lift them to the cage turning machine of the connecting bar welding station. The number of the cage turning machines is one or more, which is configured according to the production requirements;

[0024] Step 600: Connecting bar welding station: Use a cage turning machine to turn the skeleton steel bars 90 degrees and place them upright, and start welding the connecting bars; after welding, use the cage turning machine to turn the steel cage 90 degrees and place it flat;

[0025] Step 700: Tenon and groove welding station: manually cooperate with the gantry crane to lift the steel cage to the tenon and groove welding station for tenon and groove steel bar welding; after welding, lift it to the finished steel cage transport vehicle in the finished product transport unit, and transport it to the concrete assembly line for mold placement.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] The steel cage processing production line for shield segments provided by the present invention has a mold frame vehicle that can move cyclically, and workers at each workstation only need to repeat the same operation continuously, which has low requirements on the comprehensive quality of welding workers; it does not require a large amount of material preparation, reduces the number of mold frames and material storage racks, reduces the number of times steel bars are transported, saves space, and is easy to maintain civilized construction. The workers have clear professional division of labor, saves a lot of costs, has higher work efficiency, and requires fewer personnel. The steel cage processing production line provided by the present invention places the steel cage mold frame for the segment on a self-propelled low-pressure rail trolley, moves to designated workstations through the trolley, and moves to the next workstation after the operator completes the designated work content, realizing streamlined operation, breaking the traditional steel bar processing model, and significantly improving the degree of mechanization. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0029] Figure 1 It is a layout diagram of a production line for processing steel cages for shield segments of the present invention;

[0030] Figure 2 It is a layout diagram of the cage body welding unit in the steel cage processing production line for shield segments of the present invention;

[0031] Figure 3 It is a schematic diagram of the three-dimensional structure of the transfer device in the steel cage processing production line for shield segments of the present invention;

[0032] Figure 4 It is a three-dimensional structural schematic diagram of a mold frame vehicle in a production line for processing steel cages for shield segments of the present invention;

[0033] Figure 5 It is a layout diagram of a stirrup manufacturing unit in a steel cage processing production line for shield segments of the present invention;

[0034] Figure 6 It is a layout diagram of a set of automatic arc bending machines in a production line for processing steel cages for shield segments of the present invention;

[0035] Figure 7 It is a side view of a mold frame vehicle in a production line for processing steel cages for shield segments of the present invention;

[0036] Figure 8 It is a front view of a mold frame vehicle in a production line for processing steel cages for shield segments of the present invention;

[0037] Fig. 9 It is a process flow chart of the production method of the present invention for producing a steel cage.

[0038] In the figure, 1, cutting unit; 2, bending unit; 21, surface reinforcement bending unit; 22, bottom reinforcement bending unit; 3, stirrup making unit; 311, wire rod placement area; 32, wire rod support rack; 33, straightening machine; 34, CNC stirrup bending machine; 35, stirrup finished product placement rack; 4, cage welding unit; 41, U-shaped track; 411, translation track; 412, vertical track; 42, tire mold frame car; 421, tire mold car; 422, mold frame; 43, stirrup installation station; 44, bottom reinforcement installation station; 45, surface reinforcement installation station; 46, first welding station; 47, second welding station; 5, accessory welding unit; 51, connecting reinforcement welding station; 52, concave and convex tenon welding station; 6, finished product transportation unit; 7, transfer device; 71, transfer track; 72, transfer vehicle; 73, reinforcement frame; 8, ferry vehicle. DETAILED DESCRIPTION

[0039] To make the purpose, technical solution and advantages of the present invention clearer, the technical solution of the present invention will be described in detail below. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other implementation methods obtained by ordinary technicians in this field without creative work belong to the scope of protection of the present invention.

[0040] like Figure 1As shown, the present invention provides a steel cage processing production line for shield segments, comprising a cutting unit 1, an arc bending unit 2, a stirrup making unit 3, a cage body welding unit 4, an accessory welding unit 5 and a finished product transportation unit 6, the cutting unit 1 and the arc bending unit 2 are connected for material conveying, the accessory welding unit 5 and the finished product transportation unit 6 are connected for material conveying, the arc bending unit 2 and the stirrup making unit 3 are arranged side by side on one side of the cage body welding unit 4, and the accessory welding unit 5 and the finished product transportation unit 6 are arranged side by side on the other side of the cage body welding unit 4; the cage body welding unit 4 comprises a U-shaped track 41 and a tire mold frame trolley 42, the tire mold frame trolley 42 can carry out cyclic material connection between the arc bending unit 2, the stirrup making unit 3 and the accessory welding unit 5, and specifically, the tire mold frame trolley 42 receives the steel cage components sent by each processing unit at each workstation.

[0041] Specifically, the cutting unit 1 is used to cut the steel bar according to the set length. The cutting unit 1 adopts the fully automatic shearing machine in the prior art and is equipped with an automatic conveying device. The bending unit 2 is arranged beside the automatic conveying device. The automatic conveying device is a chain-driven conveying line. A step feeding structure is arranged on the conveying line to be able to convey steel bars of different lengths to the bending unit 2 located at different positions of the conveying line. In the present invention, the automatic conveying device and the fully automatic shearing machine are both implemented by the prior art products. The present invention does not make any technical improvements to this, so it will not be repeated here.

[0042] like Figure 6 As shown, the bending unit 2 includes a face rib bending unit 21 and a bottom rib bending unit 22 arranged side by side, and the face rib bending unit 21 and the bottom rib bending unit 22 are both connected to the cage body assembly welding unit 4 for material transportation through a transfer device 7. It should be noted that in the present invention, the face rib bending unit 21 and the bottom rib bending unit 22 are both implemented by an automatic bending machine in the prior art, and a storage rack for the face rib and a storage rack for the bottom rib are respectively arranged beside the bending machine. The face rib processed by the face rib bending unit 21 is transported to the cage body assembly welding unit 4 through the transfer device 7 for face rib assembly, and the bottom rib processed by the bottom rib bending unit 22 is transported to the cage body assembly welding unit 4 through the transfer device 7 for bottom rib assembly. The face rib bending unit 21 and the bottom rib bending unit 22 are arranged side by side beside the automatic conveyor.

[0043] like Figure 5 As shown, the stirrup production unit 3 includes a wire rod placement area 311, a wire rod support rack 32 after uncoiling, a straightening machine 33, a CNC stirrup bending machine 34, and a stirrup finished product placement rack 35. It should be noted that the stirrup production unit 3 is implemented using products in the existing technology.

[0044] The cage body welding unit 4 includes a U-shaped track 41, a tire mold frame 42 movably arranged on the U-shaped track 41, and a stirrup installation station 43, a bottom reinforcement installation station 44, a surface reinforcement installation station 45, a first welding station 46 and a second welding station 47 arranged at intervals along the U-shaped track 41, and the stirrup installation station 43, the bottom reinforcement installation station 44, the surface reinforcement installation station 45, the first welding station 46 and the second welding station 47 are respectively arranged corresponding to the stirrup production unit 3, the bottom reinforcement bending unit 22, the surface reinforcement bending unit 21, the top and bottom reinforcement storage unit and the auxiliary steel bar storage unit, the tire mold frame 42 circulates between the various stations, and the movement mode of the tire mold frame 42 can be a pre-set fixed mode, or it can be adjusted according to the on-site conditions, with an automatic control function; there is also a manual intervention mode.

[0045] It should be noted here that the stirrup making unit 3, the bottom bar bending unit 22, and the surface bar bending unit 21 are arranged side by side in sequence on the outside of one long side of the U-shaped track 41, and the top and bottom bar storage units and the auxiliary steel bar storage units are arranged side by side on the inside or outside of the other long side of the U-shaped track 41; when the tire mold frame 42 moves between various stations, it can be operated according to the set operation mode, or it can be adjusted according to actual needs, or it can be operated by manual intervention. The specific method can be selected as needed. If it is operated according to the set operation mode, according to the layout position distance and other parameters of the processing production line in the factory, the moving time between two adjacent stations can be set in advance in the control module, and the stay time at a certain station can be set. Moreover, the distance between adjacent stations is the actual spacing input into the control module in advance. According to the moving distance and the required moving time, the running speed of the driving device that drives the tire mold frame 42 to move can be calculated, and the running speed of the driving module is set in the control module, and the tire mold frame 42 is accurately moved to the next station and stopped according to the running time.

[0046] As an optional embodiment of the present invention, the U-shaped track 41 is a closed track, including a long straight side and a short arc side, and there is an arc transition structure between the short arc side and the long straight side to facilitate the smooth movement of the tire mold frame vehicle 42.

[0047] As another optional embodiment of the present invention, the U-shaped track 41 includes a translation track 411 and a vertical track 412 separated from each other, the translation track 411 is the long side, and the vertical track 412 is the short side; a ferry 8 is provided on the vertical track 412, and when the tire mold frame 42 moves to both ends of a translation track 411, the ferry 8 can transfer the tire mold frame 42 to another translation track 411. The vertical track 412 in the present invention is set in a pit, and the structure of the ferry 8 is realized by using products in the prior art. A connecting track with the same specifications as the translation track 411 is provided on the top of the ferry 8, and the connecting track on the top of the ferry 8 is in the same plane as the translation track 411. When the shuttle bus 8 moves to one end of the translation track 411, the tire mold frame car 42 moves to the connecting track, and then the shuttle bus 8 moves to the other side of the translation track 411. When the shuttle bus 8 moves to the translation track 411 on the other side, the tire mold car 42 moves to the translation track 411. Thus, the tire mold car 42 completes a full circle cycle.

[0048] In order to improve work efficiency, the surface bar bending unit 21 and the bottom bar bending unit 22 each include two sets of bending machines, which are arranged opposite to each other, and the discharge ports of the two sets are arranged opposite to each other. A receiving rack is arranged on the front side of the bending machine, and the steel bars cut by the cutting unit 1 are transported to the receiving rack through a chain conveyor line. The steel bars are manually taken out and sent to the bending machine for bending. The bent steel bars are sent to the transfer device 7 or to the storage rack of the surface bar or the storage rack of the bottom bar to wait for the transfer device 7 to transport them away; the number of transfer devices 7 is four, two in a group, and they are respectively arranged between the two sets of bending machines. That is to say, two sets of side-by-side transfer devices 7 are arranged between the two sets of bending machines, and the curved bottom bars or surface bars produced by the two sets of bending machines are transported to the cage assembly welding unit 4 through the two sets of transfer devices 7 to carry out the installation process of the bottom bars and surface bars.

[0049] It should be noted that, in the present invention, the arc bending machine is also implemented by products in the prior art, and can bend the cut steel bars into arc shapes.

[0050] like Figure 3 As shown, further, the transfer device 7 includes a transfer track 71, a transfer vehicle 72, a reinforcement frame 73 and a push assembly, the transfer track 71 is perpendicular to the U-shaped track 41, the transfer vehicle 72 is slidably arranged on the transfer track 71, the reinforcement frame 73 is arranged on the transfer vehicle 72, and the push assembly is arranged on the reinforcement frame 73. The transfer vehicle 72 can be moved between the upstream and downstream equipment manually or automatically. The transfer vehicle 72 is implemented by a flatbed vehicle in the prior art.

[0051] Furthermore, the reinforcement frame 73 includes a vertical support and a horizontal support rod connected to the top of the two vertical supports. The vertical support is a right triangle structure, and the top is a hypotenuse, that is, the long straight side of the vertical support is fixedly connected to the top of the platform on the top of the transfer vehicle 72. The vertical support is arranged along the length direction of the platform of the transfer vehicle 72, and its length is the same as the length of the platform; the two horizontal support rods are respectively connected to the highest position and the middle position of the vertical support. Since the top of the vertical support is a hypotenuse, there is a height difference between the two horizontal support rods, that is, a downward oblique support structure is formed between the two vertical supports through the two horizontal support rods, and the steel bars can be erected on the two horizontal support rods; reinforcement components are arranged on the two horizontal support rods. The reinforcement components can be used to regularly arrange the steel bars to be transported. It should be noted that the regular arrangement here refers to arranging the steel bars at a fixed interval, which is the same as the steel bar interval in the steel cage, that is, the steel bars arranged at the fixed interval are exactly the same as the steel bar arrangement positions in the steel cage, so that the steel bars transported to the cage body welding unit 4 via the transfer device 7 can be welded to form the steel cage without adjusting the interval again, thereby reducing the steel bar adjustment link of the next process equipment.

[0052] The reinforcement assembly includes a plurality of baffles arranged along the length direction of the horizontal support rod, and a reinforcement placement portion is formed between two adjacent baffles, and each reinforcement placement portion is directly opposite to the bottom reinforcement or surface reinforcement placement position of the reinforcement cage in the cage body welding unit 4. The accompanying drawings of the present invention only illustrate the structure of one embodiment of the baffle, in which the baffle is shuttle-shaped.

[0053] In order to facilitate the removal of the steel bars from the transfer device 7, the push assembly is a bearing arranged at both ends of the horizontal support rod, that is, the horizontal support rod is rotatably arranged on the vertical bracket through the push assembly, and a locking structure is also arranged between the horizontal support rod and the vertical bracket, and the horizontal support rod can be in a rotatable state and a position locked state through the locking structure. Specifically, the locking structure is implemented by a product in the prior art, such as a latch used on a door, which is movably arranged on the vertical bracket and can be vertically lifted or horizontally moved, and the position of the horizontal support rod is locked when the latch abuts against the surface of the horizontal support rod.

[0054] like Figure 7 and Figure 8 As shown, the tire mold frame vehicle 42 includes a tire mold vehicle 421 and a mold frame 422 . The tire mold vehicle 421 is slidably disposed on the U-shaped track 41 , and the mold frame 422 is disposed on the tire mold vehicle 421 .

[0055] like Figure 4As shown, specifically, the tire mold vehicle 421 is implemented by a flatbed vehicle in the prior art. The mold frame 422 includes a plurality of transverse braces and a plurality of vertical braces, all of which are cross-shaped and arranged in a cross shape, and the top surface of the transverse braces is flush with the top surface of the vertical braces at the corresponding position. The platform width direction of the top of all the transverse braces tire mold vehicles 421 is arranged, and the platform length direction of the top of all the vertical braces tire mold vehicles 421 is arranged. The top of the transverse braces is a straight structure, and the top of the vertical braces is a curved structure. It should be noted here that the curved structure at the top of the vertical braces is exactly the same as the curved structure of the curved steel bars constituting the top and bottom surfaces of the steel cage. The mold frame 422 also includes two baffles arranged vertically at the top of the two ends of the transverse braces. By setting the baffles, a groove with two sides limited is formed at the top of the mold frame 422, and the position of the steel cage can be limited by the baffles. Specifically, the distance between the two baffles is equal to or greater than the width of the steel cage.

[0056] The accessory assembly welding unit 5 includes a connecting rib welding station 51 and a mortise and tenon welding station 52 which are arranged side by side. The connecting rib welding station 51 is connected to the second welding station 47 and the mortise and tenon welding station 52 through a gantry crane. That is, after the steel cage is welded at the second welding station 47, it is lifted into the connecting rib welding station 51 through a gantry crane. After the connecting rib welding is completed, it is lifted into the mortise and tenon welding station 52 through a gantry crane. After the mortise and tenon welding is completed, it is lifted into the finished product transport unit 6 through a gantry crane to transport the finished product out. The finished product transport unit 6 is connected to the mortise and tenon welding station 52 through a gantry crane.

[0057] Furthermore, the connecting bar welding station 51 includes a cage turning machine. After the steel cage is hoisted to the connecting bar welding station 51, it is turned 90 degrees by the cage turning machine to perform the connecting bar welding. After the welding is completed, the cage turning machine is operated again to turn the steel cage back to the initial position, and then it is hoisted away by the door crane to perform the mortise and tenon welding. In the present invention, the connecting bar welding station 51 and the mortise and tenon welding station 52 also adopt the existing technical products, and the present invention does not make any technical improvements thereto, so it will not be described in detail.

[0058] In order to further improve the automation level of the processing production line, a control module electrically connected to the tire mold frame 42 is also included. The control module can drive the tire mold frame 42 to move circularly on the U-shaped track 41. The circular movement mode has a pre-set fixed mode, a customized mode adjusted according to actual conditions, and a manual mode of manual intervention; when the pre-set fixed mode is used, the tire mold frame 42 moves on the U-shaped track 41 in an operation mode of fixed movement time and fixed residence time. The fixed movement time referred to here refers to the movement time between two adjacent workstations; the fixed residence time sets the residence time of each workstation. The control module is implemented by programming using existing technology products.

[0059] In order to improve production efficiency, the number of tire mold racks 42 is at least 2. In one embodiment of the present invention, the number of tire mold racks 42 is 10, and the transfer device 7 is 4.

[0060] Embodiment 1:

[0061] The traditional steel cage processing production line includes the following processes: the steel bars are cut using a fully automatic shearing machine or a hydraulic cutting machine, and human labor cooperates with a gantry crane to bend the cut steel bars into arcs, and the bent arc-shaped steel bars are stored in the semi-finished product storage rack; the semi-finished products are hoisted from the storage rack to the welding area storage rack by human labor and a gantry crane for standby use; the welding station in the welding workshop uses a fixed steel membrane rack, and the welder installs the stirrups, bottom bars, and surface bars on the membrane rack in turn and welds them; after the steel skeleton is welded into a whole, the skeleton is moved away from the membrane rack, turned 90 degrees and placed upright, and the welding of the connecting bars and the mortise and tenon steel bars begins. After the welding is completed, human labor cooperates with the gantry crane to hoist the steel cage to the finished product storage area for standby use.

[0062] In order to create an intelligent, information-based, mechanized and factory-based industrial base, and at the same time, to further improve the standardized management level, work efficiency and overall image of the industrial base, a new steel cage processing production line for shield segments is proposed based on the analysis of the traditional construction process of steel cage processing. The welding stations of the welding workshop in the steel cage processing production line of the present invention are divided into seven flow stations, namely, stirrup installation station 43, bottom reinforcement installation station 44, surface reinforcement installation station 45, first welding station 46 and second welding station 47, connecting reinforcement welding station 51 and concave and convex tenon welding station 52. (10) mold frames 422 are placed on 10 movable track mold vehicles 421, and the mold vehicles 421 circulate on the U-shaped track 41 or the circular track, and the first five workstations are arranged in a circle along the circular track or the U-shaped track 41; the circularly movable mold frame vehicle 42 passes through the stirrup installation station 43, the bottom reinforcement installation station 44, the surface reinforcement installation station 45, the first welding station 46 and the second welding station 47 in sequence to complete the welding of the steel cage frame, and then uses a gantry crane to lift it away from the U-shaped track 41 and then passes through the connecting reinforcement welding station 51 and the mortise and tenon welding station 52 in sequence to complete a complete steel cage production cycle.

[0063] (I) First station: stirrup installation station 43

[0064] The production of stirrups is completed by the stirrup production unit 3. Specifically, the large stirrups, medium stirrups or small stirrups required for the steel cage are produced in advance using a CNC stirrup bending machine. After the tire mold frame 42 is in place at the stirrup installation station 43, the large stirrups, medium stirrups or small stirrups in place are manually installed on the tire mold frame 42. The operation time of this station is 12 minutes; after the operation is completed, the tire mold frame 42 moves to the bottom reinforcement installation station 44, and the moving time is 2 minutes.

[0065] (II) Second station: Bottom rib installation station 44

[0066] The bottom reinforcement is made in the cutting unit 1 and the bottom reinforcement bending unit 22. Specifically, the reinforcement cutting adopts a fully automatic shearing machine equipped with an automatic conveying device, and the cut reinforcement is conveyed to the storage rack of the fully automatic bending machine according to a pre-set program. The storage rack automatically feeds the bending machine in the form of chain transmission + step feeding (chain conveyor belt). After the bottom reinforcement is bent and formed, it is manually placed on the reinforcement frame 73 in the transfer device 7 according to the three-dimensional spatial position of the bottom reinforcement design. The length of the reinforcement frame 73 is half the length of the bottom reinforcement, so that one end of the bottom reinforcement is higher and suspended in the air, and the other end is temporarily fixed to the lower end of the reinforcement frame 73. The transfer track 71 is perpendicular to the annular tire membrane frame track, that is, the U-shaped track 41. The transfer vehicle 72 moves to the bottom reinforcement installation station 44 through the transfer track 71 in advance. After the tire mold frame vehicle 42 is in place, the push assembly at the lower end of the reinforcement frame 73 is used to push all the bottom reinforcements into the mold frame 422 of the tire mold frame vehicle 42. The bottom ribs falling into the mold frame 422 are manually placed in order. The tire mold frame vehicle 42 moves along the U-shaped track 41 to the rib installation station 45. The transfer vehicle 72 returns to the bending machine for the next batching. The bottom rib installation station 44 takes 12 minutes to operate, and the movement time from the bottom rib installation station 44 to the rib installation station 45 is 2 minutes.

[0067] (III) The third station: gluten installation station 45

[0068] Similarly, in the second workstation - the bottom reinforcement installation workstation 44, the rib reinforcement production is completed in the cutting unit 1 and the rib bending unit 21. Specifically, the rib reinforcement cutting adopts a fully automatic shearing machine equipped with an automatic conveying device, and the cut steel bars are conveyed to the storage rack of the fully automatic bending machine according to a preset program. The storage rack automatically feeds the bending machine in the form of chain transmission + step feeding (chain conveyor belt). After the ribs are bent and formed, they are manually placed on the reinforcement dividing frame 73 in the transfer device 7 according to the three-dimensional spatial position of the ribs design. The length of the reinforcement dividing frame 73 is half the length of the ribs, so that one end of the ribs is higher and suspended in the air, and the other end is temporarily fixed to the lower end of the reinforcement dividing frame 73. The transfer track 71 is perpendicular to the annular tire membrane frame track, that is, the U-shaped track 41. The transfer vehicle 72 moves to the gluten installation station 45 through the transfer track 71 in advance. After the tire mold frame vehicle 42 is in place, the push assembly at the lower end of the triangular rib dividing frame 73 on the transfer vehicle 72 is used to push all the gluten into the mold frame 422 of the tire mold frame vehicle 42. The gluten that falls into the mold frame 422 is manually placed in order. The tire mold frame vehicle 42 moves to the first welding station 46. The transfer vehicle 72 returns to the side of the arc bending machine for the next batching. The operation time of this station is 12 minutes. The moving time to the first welding station 46 is 2 minutes.

[0069] (IV) The fourth station: the first welding station 46 (this station performs bottom reinforcement welding and stirrup welding)

[0070] After the tire mold frame 42 is in place, the connection welding between the bottom rib and the surface rib, the connection welding between the bottom rib and the stirrup, and the connection welding between the surface rib and the stirrup are carried out in sequence. When the bottom rib and the surface rib are installed at the second station to the third station, spot welding is performed for preliminary fixation. Solid welding is performed in this station, and the welding operation is performed according to the welding process regulations. The operation time of this station is 12 minutes. After welding, the tire mold frame 42 moves to the second welding station 47, and the moving time is 2 minutes.

[0071] (V) Fifth station: Second welding station 47 (other auxiliary steel bar welding is performed at this station)

[0072] After the mold frame vehicle 42 is in place, all welding except the connecting reinforcement and the concave and convex tenon reinforcement is performed. After welding, the skeleton reinforcement is lifted off the mold frame 422 by manual cooperation with the gantry crane and lifted to the cage turning machine of the connecting reinforcement welding station 51. The number of cage turning machines can be configured one or more according to the production requirements. The operation time of this station is 12 minutes.

[0073] (VI) Sixth station: connecting rib welding station 51

[0074] Use the cage turning machine to turn the frame 90 degrees and place it upright, and start welding the connecting bars. After welding, use the cage turning machine again to turn the steel cage 90 degrees and place it flat. The operation time of this station is 20 minutes.

[0075] (VII) The seventh station: tenon and mortise welding station 52

[0076] The steel cage is manually lifted to the mortise and tenon welding station 52 for mortise and tenon steel bar welding. After welding, it is lifted to the finished steel cage transport vehicle in the finished product transport unit 6 and transported to the concrete assembly line for mold placement. The operation time of this station is 20 minutes.

[0077] It should be noted that, in the present invention, the equipment used in the cutting unit 1, the bending unit 2 and the stirrup making unit 3 are all equipment used in the existing processing production line, and their automatic control operation mode can be carried out according to the control system matched when the equipment is purchased; the control module of the present invention mainly performs automatic control on the various equipment in the cage body welding unit 4. Since the distance layout position between each workstation is fixed, the interval between each workstation can be calculated during the design, and the moving time and the stay time between each workstation are fixed. Therefore, in the control module of the present invention, a motor and a PLC control board can be used to realize the automatic movement control of the tire mold frame vehicle 42, the shuttle vehicle 8 and the transfer vehicle 72.

[0078] like Figure 2 As shown, the operation mode is introduced by taking the arrangement of 10 tire mold racks 42 on the U-shaped track 41 as an example. Figure 2 As shown, the tire mold frame vehicles 42 are numbered 1-10 respectively, and the stirrup installation station 43, the bottom reinforcement installation station 44, the surface reinforcement installation station 45, the first welding station 46 and the second welding station 47 located beside the U-shaped track 41 are defined as the first station, the second station, the third station, the fourth station and the fifth station respectively. When the equipment operation time is 0, that is, the initial stage, the 10 tire mold frame vehicles 42 are divided into five groups and located at five stations respectively. Manual work begins to place stirrups on the two tire mold frame vehicles 42 located at the first station. It takes about 10 minutes to place stirrups. Considering the fault tolerance and the influence of the speed of action, the system sets the dwell time to 12 minutes. Once the operation reaches 12 minutes, the 10 tire mold frame vehicles 42 move together. Due to the distance between adjacent stations, the system stops at 12 minutes. The moving time is 2 minutes. When the system runs for 14 minutes, the No. 1 and No. 2 tire mold frame vehicles 42 move to the second station to install the bottom reinforcement, and the No. 9 and No. 10 tire mold frame vehicles 42 move to the first station to install the stirrups. The other tire mold frame vehicles 42 move back one station in turn. The bottom reinforcement installation time is about 10 minutes. Considering the fault tolerance and the speed of movement, after staying for 12 minutes, the 10 tire mold frame vehicles 42 continue to move and move to the next station at 2 minutes. At this time, when the system runs for 26 minutes, 10 tire mold frame vehicles 42 move. When the system runs for 28 minutes, the No. 1 and No. 2 tire mold frame vehicles 42 move to the third station to install the surface reinforcement. And so on, the stay time at each station is 12 minutes and the movement time is 2 minutes. In total, after the welding of all parts of the steel cage skeleton except the connecting ribs and the concave and convex tenon is completed, the system running time is 70 minutes. This reciprocating cycle is continuously realized to realize the welding and production of each steel cage skeleton.

[0079] Compared with traditional segment reinforcement cage processing, the segment reinforcement cage processing line has higher work efficiency, requires fewer personnel, has clearer division of labor among workers, and reduces the number of hoisting times.

[0080] The segment reinforcement cage processing production line places the segment membrane on the mold frame 42, and moves it to the designated workstations through the mold frame 42. After the operator completes the designated work content, it moves to the next workstation to realize streamlined operation.

[0081] like Fig. 9 As shown, the present invention provides a production method for producing a steel cage using a steel cage processing production line for shield segments, and the production and processing steps of the steel cage are completed in sequence at the following seven stations:

[0082] Step 100, stirrup installation station: the CNC stirrup bending machine is used to make the stirrups required for the steel cage, and after the tire formwork frame vehicle is positioned at the stirrup installation station, the positioned stirrups are manually installed on the tire formwork frame vehicle, and the tire formwork frame vehicle moves to the next station, the bottom reinforcement installation station;

[0083] Step 200: Bottom reinforcement installation station: the steel bars cut by the fully automatic shearing machine are transferred to the storage rack of the fully automatic bending machine, and the storage rack is automatically loaded; after the bottom reinforcement is bent and formed, it is placed on the reinforcement frame in the transfer device, and the pushing component at the bottom of the reinforcement frame is used to push the bottom reinforcement into the mold frame of the tire mold frame vehicle; the bottom reinforcement in the mold frame is manually placed, and the tire mold frame vehicle moves along the track to the next station, the surface reinforcement installation station;

[0084] Step 300: Gluten installation station: The steel bars cut by the fully automatic shearing machine are transferred to the material storage rack of the fully automatic bending machine, and the material storage rack is automatically loaded; after the gluten is bent and formed, it is placed on the rib frame of the transfer device, and the pushing component at the bottom of the triangular rib frame on the transfer vehicle is used to push the gluten into the mold frame of the tire mold frame vehicle; the gluten in the mold frame is manually placed, and the tire mold frame vehicle moves to the next station, the first welding station;

[0085] Step 400: First welding station: sequentially perform connection welding of bottom reinforcement and surface reinforcement, connection welding of bottom reinforcement and stirrup, connection welding of surface reinforcement and stirrup. When installing the bottom reinforcement and surface reinforcement at the bottom reinforcement welding station and the surface reinforcement welding station, spot welding will be performed for preliminary fixation. The tire mold drives to the next station, the second welding station;

[0086] Step 500: Second welding station: perform all welding except for the connecting bars and the concave and convex tenon steel bars to form the skeleton steel bars; after welding, manually cooperate with the gantry crane to lift the skeleton steel bars away from the formwork and lift them to the cage turning machine of the connecting bar welding station. The number of the cage turning machines is one or more, which is configured according to the production requirements;

[0087] Step 600: Connecting bar welding station: Use a cage turning machine to turn the skeleton steel bars 90 degrees and place them upright, and start welding the connecting bars; after welding, use the cage turning machine to turn the steel cage 90 degrees and place it flat;

[0088] Step 700: Tenon and groove welding station: manually cooperate with the gantry crane to lift the steel cage to the tenon and groove welding station for tenon and groove steel bar welding; after welding, lift it to the finished steel cage transport vehicle in the finished product transport unit, and transport it to the concrete assembly line for mold placement;

[0089] As an optional embodiment of the present invention, when operating in a pre-set fixed mode, the tire mold frame vehicle runs between adjacent workstations for 2 minutes and stays at each workstation for 12 minutes. Of course, the above two fixed values ​​can also be adjusted according to the time required for the processing station and the distance between the processing stations.

[0090] The processing production line and production method provided by the present invention are not only applicable to processing workshops for steel cages, but also to processing workshops for other products. It is sufficient to connect the various processing equipment that make up the product through the U-shaped track 41. Personnel only need to be arranged at each workstation to perform assembly and assembling actions. There is no need for frequent walking, and the work is single. The quality requirements for operators at different workstations can be set as needed. Moreover, since the vehicles running on the U-shaped track 41 can run automatically, the running time and the dwell time can be controlled, the automation level of the production line is greatly improved, and the work efficiency is greatly improved.

[0091] First of all, it should be explained here that “inward” refers to the direction toward the center of the accommodating space, and “outward” refers to the direction away from the center of the accommodating space.

[0092] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate directions or positional relationships based on the attached Figure 1 The orientation or positional relationship shown is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0093] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In the description of the present invention, the meaning of "plurality" is at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0094] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0095] In the present invention, unless otherwise clearly specified and limited, a first feature being "above" or "below" a second feature may mean that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium. Moreover, a first feature being "above", "above" or "above" a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being "below", "below" or "below" a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0096] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine the different embodiments or examples described in this specification and the features of the different embodiments or examples, without contradiction.

[0097] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A steel cage processing production line for shield segments, characterized in that: It comprises a cutting unit, an arc bending unit, a stirrup making unit, a cage body welding unit, an accessory welding unit and a finished product transport unit, wherein the cutting unit is connected to the arc bending unit for material conveying, the accessory welding unit is connected to the finished product transport unit for material conveying, the arc bending unit and the stirrup making unit are arranged side by side on one side of the cage body welding unit, and the accessory welding unit and the finished product transport unit are arranged side by side on the other side of the cage body welding unit; the cage body welding unit comprises a U-shaped track and a tire mold frame, and the tire mold frame can carry out cyclic material connection between the arc bending unit, the stirrup making unit and the accessory welding unit; The bending unit comprises a surface rib bending unit and a bottom rib bending unit arranged side by side, and both the surface rib bending unit and the bottom rib bending unit are connected to the cage body assembly welding unit for material transportation via a transfer device; The cage body assembly welding unit comprises a U-shaped track, a tire formwork frame trolley movably arranged on the U-shaped track, and a stirrup installation station, a bottom reinforcement installation station, a surface reinforcement installation station, a first welding station and a second welding station arranged at intervals along the U-shaped track, and the stirrup installation station, the bottom reinforcement installation station, the surface reinforcement installation station, the first welding station and the second welding station are respectively arranged corresponding to the stirrup production unit, the bottom reinforcement bending unit, the surface reinforcement bending unit, the top and bottom reinforcement storage unit and the auxiliary steel bar storage unit, and the tire formwork frame trolley circulates between the various stations; The U-shaped track includes a translation track and a vertical movement track which are separated from each other. A shuttle bus is arranged on the vertical movement track. When the tire mold frame trolley moves to two ends of one translation track, the tire mold frame trolley can be transferred to another translation track by the shuttle bus.

2. The steel cage processing production line for shield segments according to claim 1 is characterized in that: The surface rib bending unit and the bottom rib bending unit each include two sets of bending machines, and the number of the transfer devices is four, two in a group, and are respectively arranged between the two sets of the bending machines.

3. The steel cage processing production line for shield segments according to claim 1 is characterized in that: The transfer device includes a transfer track, a transfer vehicle, a reinforcement frame and a pushing assembly. The transfer track is perpendicular to the U-shaped track, the transfer vehicle is slidably arranged on the transfer track, the reinforcement frame is arranged on the transfer vehicle, and the pushing assembly is arranged on the reinforcement frame.

4. The steel cage processing production line for shield segments according to claim 1 is characterized in that: The tire mold frame vehicle comprises a tire mold vehicle and a mold frame. The tire mold vehicle is slidably arranged on the U-shaped track, and the mold frame is arranged on the tire mold vehicle.

5. The steel cage processing production line for shield segments according to claim 1 is characterized in that: The accessory assembly welding unit includes a connecting rib welding station and a mortise and tenon welding station arranged side by side. The connecting rib welding station is connected to the second welding station and the mortise and tenon welding station through a gantry crane, and the finished product transportation unit is connected to the mortise and tenon welding station through a gantry crane.

6. The steel cage processing production line for shield segments according to claim 1 is characterized in that: It also includes a control module electrically connected to the tire mold frame vehicle, and the tire mold frame vehicle can be driven by the control module to move circularly on the U-shaped track.

7. A method for producing a steel cage using the steel cage processing line for shield segments according to any one of claims 1 to 6, characterized in that: The production and processing steps of the steel cage are completed in the following seven stations: Step 100, stirrup installation station: the CNC stirrup bending machine is used to make the stirrups required for the steel cage, and after the tire formwork frame vehicle is positioned at the stirrup installation station, the positioned stirrups are manually installed on the tire formwork frame vehicle, and the tire formwork frame vehicle moves to the next station, the bottom reinforcement installation station; Step 200: Bottom reinforcement installation station: the steel bars cut by the fully automatic shearing machine are transferred to the storage rack of the fully automatic bending machine, and the storage rack is automatically loaded; after the bottom reinforcement is bent and formed, it is placed on the reinforcement frame in the transfer device, and the pushing component at the bottom of the reinforcement frame is used to push the bottom reinforcement into the mold frame of the tire mold frame vehicle; the bottom reinforcement in the mold frame is manually placed, and the tire mold frame vehicle moves along the track to the next station, the surface reinforcement installation station; Step 300: Gluten installation station: The steel bars cut by the fully automatic shearing machine are transferred to the material storage rack of the fully automatic bending machine, and the material storage rack is automatically loaded; after the gluten is bent and formed, it is placed on the rib frame of the transfer device, and the pushing component at the bottom of the triangular rib frame on the transfer vehicle is used to push the gluten into the mold frame of the tire mold frame vehicle; the gluten in the mold frame is manually placed, and the tire mold frame vehicle moves to the next station, the first welding station; Step 400: First welding station: sequentially perform connection welding between bottom reinforcement and surface reinforcement, connection welding between bottom reinforcement and stirrup, and connection welding between surface reinforcement and stirrup. When installing the bottom reinforcement and surface reinforcement at the bottom reinforcement welding station and the surface reinforcement welding station, spot welding will be performed for preliminary fixation. The tire mold frame vehicle moves to the next station, the second welding station; Step 500: Second welding station: perform all welding except for the connecting bars and the concave and convex tenon bars to form the skeleton bars; after welding, manually cooperate with the gantry crane to lift the skeleton bars from the formwork and lift them to the cage turning machine of the connecting bar welding station. The number of cage turning machines is one or more, which are configured according to the production requirements. The tire formwork frame car moves to the stirrup installation station to carry out the second round of cycle production process; Step 600: Connecting bar welding station: Use a cage turning machine to turn the skeleton steel bars 90 degrees and place them upright, and start welding the connecting bars; after welding, use the cage turning machine to turn the steel cage 90 degrees and place it flat; Step 700: Tenon and groove welding station: manually cooperate with the gantry crane to lift the steel cage to the tenon and groove welding station for tenon and groove steel bar welding; after welding, lift it to the finished steel cage transport vehicle in the finished product transport unit, and transport it to the concrete assembly line for mold placement.

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