PCCP Socket and Spigot Full-Automation Production System and Process

Abstract

This application relates to a PCCP socket and spigot manufacturing device and process, and particularly to a fully automated production system and process for PCCP sockets and spigots; it includes a feeding component, a flipping and transporting component, a belt conveyor, a processor, a 90-degree flipping drum, a drum conveyor, a plate rolling machine, and a welding machine; the flipping and transporting component that can adsorb and flip the sheet material onto the belt conveyor is installed between the feeding component and the belt conveyor; a visual recognition device and a turning mechanism are sequentially installed between the head and the end of the belt conveyor. Due to the implementation of the above technical solution, this application has a high degree of automation, can achieve automatic splitting, automatic rolling into a circle, and automatic welding; improves the safety factor, greatly improves the manufacturing efficiency, improves the product quality, only requires one person to be on duty throughout the process, reduces the labor force; and is suitable for popularization and application.

Description

Technical Field

[0001] This application relates to a PCCP socket and spigot manufacturing device and process, and particularly to a fully automated production system and process for PCCP sockets and spigots. Background Art

[0002] Prestressed concrete cylinder pipe (abbreviated as PCCP in English) refers to a pipe made by winding circumferential prestressed steel wires on the outer side of a concrete pipe core with a steel cylinder and making a cement mortar protective layer. It is generally used for urban water supply and drainage main pipes, industrial water transmission pipelines, farmland irrigation, factory pipe networks, power plant make-up water pipes and cooling water circulation systems, inverted siphons, pressure tunnel pipelines, pipe trenches, pipe galleries and deep-buried culverts, etc.

[0003] The production of PCCP is divided into: socket and spigot production, steel cylinder production, core concrete production, winding circumferential prestressed steel wires, and roller spraying of the mortar protective layer.

[0004] In China, when manufacturing prestressed concrete cylinder pipes according to GB / T 19685, the traditional method is used for making sockets and spigots. The required equipment includes: a roll-forming machine, a socket and spigot welding press plate machine, a welding platform, a socket roller forming machine, a bulging machine, etc. The specific operation is as follows: The cut-to-length socket and spigot steel plates are hoisted by a crane and placed on the roll-forming machine for roll-forming. Then, the formed socket and spigot are hoisted by a crane and placed on the socket and spigot welding press plate machine. The inner weld is welded manually with manual alignment. After the inner weld is welded, it is hoisted by a crane to the welding platform, rotated 180° to turn the weld to the top, and the outer weld is welded manually.

[0005] During the manufacturing process, the number of hoists for the socket and spigot is relatively large, and the sling causes small quality defects on the surface of the socket and spigot material, which requires special grinding and repair during the finished product. The welded joint grinding needs to be smooth and burr-free, and it takes at least 20 minutes for the operator to keep grinding. Since the welds are manually welded, there are cases where the welding is unqualified. In terms of labor, at least 5 operators are required for the entire production of the socket and spigot. Summary of the Invention

[0006] The purpose of this application is to propose a fully automated production system and process for PCCP sockets and spigots that saves time and improves efficiency.

[0007] One of the technical solutions of this application is realized as follows: a fully automatic production system for PCCP socket and spigot, which includes a feeding component, a flipping and transporting component, a belt conveyor line, a processor, a 90-degree flipping roller, a roller conveyor line, a plate rolling machine and a welding machine; the flipping and transporting component capable of adsorbing and flipping the sheet material onto the belt conveyor line is installed between the feeding component and the belt conveyor line; a visual recognition instrument and a turning mechanism are sequentially installed between the head end and the tail end of the belt conveyor line; the visual recognition instrument is connected to the input end of the processor, and the output end of the processor is connected to the turning mechanism that can switch between two states of flipping the sheet material or not affecting the sheet material transportation; the 90-degree flipping roller that can flip the sheet material and send it into the roller conveyor line is installed at the tail end of the belt conveyor line; the output end of the roller conveyor line is matched and opposite to the feeding port of the plate rolling machine, and the welding machine is installed at the position where the cylinder rolled by the plate rolling machine is located.

[0008] Further, the feeding component includes a bracket, an inclined storage rack and a sheet material support installed at the lower end of the storage rack; the storage rack is installed on the bracket, and the higher end of the storage rack is close to the belt conveyor line and the end face is unobstructed.

[0009] Further, the flipping and transporting component includes a plurality of bottom frames fixed between the feeding component and the belt conveyor line, a first through shaft is installed on the upper part of the plurality of bottom frames, a plurality of first flipping hands are fixedly installed on the first through shaft at intervals, and a first electromagnet corresponding to the higher end position of the storage rack is installed at the top of each first flipping hand; the first through shaft is connected to the motor.

[0010] Further, the belt conveyor line is composed of a plurality of synchronous and spaced belt conveyors; an interval channel for the first flipping hand to pass through when rotating is provided between adjacent belt conveyors.

[0011] Further, a plurality of 90-degree flipping rollers hinged to the side of the roller conveyor line are located at the end of the corresponding interval channel.

[0012] Further, the turning mechanism includes a second through shaft and a second flipping hand; a second through shaft with an axis position lower than the upper end face of the belt conveyor line is installed on the belt conveyor line, a plurality of second flipping hands are fixedly installed on the second through shaft at intervals and at positions higher than the upper end face of the belt conveyor line, and a second electromagnet is installed on the lower end face of the second flipping hand; the second through shaft is connected to the motor.

[0013] The second technical solution of this application is realized as follows: a fully automatic production process for PCCP socket and spigot, which is characterized by including the following steps:

[0014] In the first step, operate the lifting equipment to hoist the socket and spigot sheet material into the storage rack and place it on the sheet material support;

[0015] In the second step, the motor drives the first through-shaft to rotate. After the first electromagnet on the first flipping hand adheres to the socket plate at the highest end, start the first electromagnet to work and fix the socket plate at the highest end. The motor drives the first through-shaft to rotate in the reverse direction, the first flipping hand rotates to the interval channel, the socket plate is placed on the belt conveyor, and the first electromagnet stops working.

[0016] In the third step, the socket plate is transported along with the belt conveyor. After the visual recognition device identifies the front and back sides of the raw material, when it is identified as the front side, it is transported normally and the second flipping hand rotates to its original position. When it is identified as the back side, the second flipping hand rotates to the upper part of the upper end face of the belt conveyor along with the second through-shaft, start the second electromagnet to work, and adsorb and fix the socket plate on the back side. The motor drives the second through-shaft to rotate and turn 180 degrees. The second flipping hand turns to the lower part of the upper end face of the belt conveyor. After the socket plate is turned over in the air, it still falls onto the belt conveyor and continues to be transported downward.

[0017] In the fourth step, after the socket plate is erected by the 90-degree flipping roller, it is pushed into the rolling machine through the cooperation of the 90-degree flipping roller and the roller conveyor.

[0018] In the fifth step, the socket plate is rolled into a socket steel ring and rotates to the set working station. At this time, the inner and outer welds are directly welded by the welding machine.

[0019] Due to the implementation of the above technical solution, in this application, the socket plate in the feeding component is placed on the belt conveyor through the flipping and transferring component. The socket plate is transported along with the belt conveyor, the front and back sides of the raw material are identified by the visual recognition device, and the reverse plate is adjusted by the turning-over mechanism. The plate is erected by the 90-degree flipping component and is automatically pushed into the rolling machine for rolling under the transportation of the roller conveyor, and finally the inner and outer welds of the butt joint of the plate are welded by the welding machine. This application has a high degree of automation, can realize automatic sorting, automatic rolling, and automatic welding; improves the safety factor, greatly improves the production efficiency, improves the product quality, only requires 1 person to be on duty throughout the process, reduces the labor force, and is suitable for popularization and application. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The specific structure of this application is given by the following drawings and embodiments:

[0021] Figure 1 is the top view structural schematic diagram of the best embodiment of this application;

[0022] Figure 2 is Figure 1 the side view structural schematic diagram of...

[0023] Legend: 1. Belt conveyor line, 2. 90-degree flipping roller, 3. Roller conveyor line, 4. Support, 5. Storage rack, 6. Sheet metal support, 7. Underframe, 8. First through-shaft, 9. First flipping hand, 10. Spacing channel, 11. Second through-shaft, 12. Second flipping hand, 13. Second electromagnet, 14. Socket sheet metal, 15. First electromagnet, 16. Visual recognition instrument, 17. Plate rolling machine, 18. Welder. Detailed implementation manners

[0024] This application is not limited by the following embodiments, and the specific implementation manners can be determined according to the technical solutions of this application and the actual situation.

[0025] Embodiment 1, as Figure 1 、 2 shown, the PCCP socket full-automatic production system and process include a feeding component, a flipping and transferring component, a belt conveyor line 1, a processor, a 90-degree flipping roller 2, a roller conveyor line 3, a plate rolling machine 17, and a welder 18; the flipping and transferring component capable of adsorbing and flipping the sheet metal and transporting it onto the belt conveyor line 1 is installed between the feeding component and the belt conveyor line 1; a visual recognition instrument 16 and a turning-over mechanism are sequentially installed between the head end and the tail end of the belt conveyor line 1; the visual recognition instrument 16 is connected to the input end of the processor, and the output end of the processor is connected to the turning-over mechanism capable of switching between two states of flipping the sheet metal or not affecting the sheet metal transportation; the 90-degree flipping roller 2 capable of flipping the sheet metal and feeding it into the roller conveyor line 3 is installed at the tail end of the belt conveyor line 1; the output end of the roller conveyor line 3 is matched and opposed to the feeding port of the plate rolling machine 17, and the welder 18 is installed at the position where the cylinder rolled by the plate rolling machine 17 is located.

[0026] The socket sheet metal 14 has a front and a back. When being transported and placed, in order to save space and protect the protruding corners; they are stacked with one front and one back. Therefore, after the visual recognition instrument 16 distinguishes the raw materials, the turning-over mechanism will not perform consecutive identical actions, which can improve the overall equipment efficiency.

[0027] During operation, a stack of socket sheet metals 14 is placed into the feeding component, and the flipping and transferring component places the socket sheet metals 14 in the feeding component onto the belt conveyor line 1. When the belt conveyor line 1 transports a single socket sheet metal 14 to the roller conveyor line 3, it first passes through the visual recognition instrument 16 to distinguish the front and back of the raw materials, and then adjusts the reverse sheet metal through the turning-over mechanism.

[0028] The socket sheet metal 14 is erected by the 90-degree flipping component, and is automatically pushed into the plate rolling machine 17 for rolling under the transportation of the roller conveyor line 3, and finally the inner and outer welds of the sheet metal butt joint are welded by the welder 18; this application has a high degree of automation, can realize automatic sorting, automatic rolling into a circle, and automatic welding; improves the safety factor, greatly improves the production efficiency, improves the product quality, only requires one person to be on duty throughout the process, reduces the labor; reaches the advanced level at home and abroad, and is suitable for popularization and application.

[0029] As Figure 1 、 2 shown, the feeding component includes a bracket 4, an inclined storage rack 5, and a sheet metal support 6 installed at the lower end of the storage rack 5; the storage rack 5 is installed on the bracket 4, and the higher end of the storage rack 5 is close to the belt conveyor 1 and has no obstruction at the end face.

[0030] The unobstructed storage rack 5 is more conducive to the first electromagnet 15 for taking materials; the sheet metal support 6 can also be made movable and pushed by components such as a cylinder. In this way, when the number of socket plate materials 14 in the storage rack 5 is small, the sheet metal support 6 can be pushed upward to facilitate the picking of raw materials.

[0031] As Figure 1 、 2 shown, the flipping and transporting component includes a plurality of bottom frames 7 fixed between the feeding component and the belt conveyor 1. A first through shaft 8 is installed on the upper part of the plurality of bottom frames 7. A plurality of first flipping hands 9 are fixedly installed on the first through shaft 8 at intervals. A first electromagnet 15 corresponding to the position of the higher end of the storage rack 5 is installed at the top of each first flipping hand 9; the first through shaft 8 is connected to a motor.

[0032] As Figure 1 、 2 shown, the belt conveyor 1 is composed of a plurality of synchronous and spaced belt conveyors; an interval passage 10 for the first flipping hand to pass through is provided between adjacent belt conveyors.

[0033] As Figure 1 、 2 shown, a plurality of 90-degree flipping rollers 2 hinged to the side of the roller conveyor 3 are located at the end of the corresponding interval passage 10.

[0034] As Figure 1 、 2 shown, the turning-over mechanism includes a second through shaft 11 and a second flipping hand 12; the belt conveyor 1 is installed with a second through shaft 11 whose axis position is lower than the upper end face of the belt conveyor 1. A plurality of second flipping hands 12 are fixedly installed on the second through shaft 11 at intervals and are located above the upper end face of the belt conveyor 1. A second electromagnet 13 is installed on the lower end face of the second flipping hand 12; the second through shaft 11 is connected to a motor.

[0035] Embodiment 2, as Figure 1 、 2As shown in the figure, the fully automated production process of PCCP socket and spigot includes the following steps: The first step is to operate the lifting equipment to hoist the socket and spigot sheet material 14 into the storage rack 5 and place it on the sheet material support 6; The second step is that the motor drives the first through shaft 8 to rotate. After the first electromagnet 15 on the first flipping hand 9 adheres to the highest-end socket and spigot sheet material 14, start the first electromagnet 15 to work and fix the highest-end socket and spigot sheet material 14; The motor drives the first through shaft 8 to rotate in the reverse direction, the first flipping hand 9 rotates to the interval channel 10, the socket and spigot sheet material 14 is placed on the belt conveyor 1, and stop the first electromagnet 15 from working; The third step is that the socket and spigot sheet material 14 is transported along with the belt conveyor 1. The visual recognition instrument 16 identifies the front and back of the raw material. When it is identified as the front, it is transported normally, and the second flipping hand 12 rotates to its original position; When it is identified as the back, the second flipping hand 12 rotates to the upper part of the upper end surface of the belt conveyor 1 along with the second through shaft 11, start the second electromagnet 13 to work, and adsorb and fix the socket and spigot sheet material 14 on the back; The motor drives the second through shaft 11 to rotate and turn 180 degrees. The second flipping hand 12 turns to the lower part of the upper end surface of the belt conveyor 1. After the socket and spigot sheet material 14 is turned over in the air, it still falls onto the belt conveyor 1 and continues to be transported downward; The fourth step is that the socket and spigot sheet material 14 is erected by the 90-degree flipping roller 2 and is pushed into the plate rolling machine 17 through the cooperation of the 90-degree flipping roller 2 and the roller conveyor 3; The fifth step is that the socket and spigot sheet material 14 is rolled into a socket and spigot steel ring and rotates to the set working position. At this time, the internal and external welds are directly welded by the welding machine 18.

[0036] The plate rolling machine 17 can be a three-roll profile bending machine with a vertical shaft and horizontal rolling.

[0037] In this article, "upper", "lower", "front", "back", "left", "right", etc. are only used to represent the relative positional relationship between relevant parts, rather than limiting the absolute positions of these relevant parts.

[0038] The above technical features constitute the embodiments of this application, which have strong adaptability and implementation effects. Non-essential technical features can be increased or decreased according to actual needs to meet the needs of different situations.

Claims

1. A fully automated production system for PCCP socket and spigot joints, characterized in that: It includes a feeding component, a flipping and transferring component, a belt conveyor line, a processor, a 90-degree flipping roller, a roller conveyor line, a plate rolling machine and a welding machine; the flipping and transferring component that can adsorb and flip the sheet material onto the belt conveyor line is installed between the feeding component and the belt conveyor line; a visual recognition instrument and a turning mechanism are sequentially installed from the head end to the tail end of the belt conveyor line; the visual recognition instrument is connected to the input end of the processor, and the output end of the processor is connected to the turning mechanism that can switch between two states of flipping the sheet material or not affecting the sheet material transportation; the 90-degree flipping roller that can flip the sheet material and send it into the roller conveyor line is installed at the tail end of the belt conveyor line; the output end of the roller conveyor line is matched and opposite to the feeding port of the plate rolling machine, and the welding machine is installed at the position of the cylinder formed by the plate rolling machine; the turning mechanism includes a second through shaft and a second flipping hand; the belt conveyor line is installed with a second through shaft whose axis position is lower than the upper end surface of the belt conveyor line, and a plurality of second flipping hands are fixedly installed on the second through shaft at intervals and whose positions are higher than the upper end surface of the belt conveyor line. A second electromagnet is installed on the lower end surface of the second flipping hand; the second through shaft is connected to the motor.

2. The fully automated production system for PCCP socket and spigot joints according to claim 1, characterized in that: The feeding component includes a bracket, an inclined storage rack and a sheet material support installed at the low end of the storage rack; the storage rack is installed on the bracket, and the higher end of the storage rack is close to the belt conveyor line and the end surface is unobstructed.

3. The fully automated production system for PCCP socket and spigot joints according to claim 2, characterized in that: The flipping and transferring component includes a plurality of bottom frames fixed between the feeding component and the belt conveyor line. A first through shaft is installed on the upper part of the plurality of bottom frames, and a plurality of first flipping hands are fixedly installed on the first through shaft at intervals. A first electromagnet corresponding to the position of the higher end of the storage rack is installed on the top of each first flipping hand; the first through shaft is connected to the motor.

4. The fully automated production system for PCCP socket and spigot joints according to claim 3, characterized in that: The belt conveyor line is composed of a plurality of synchronous and spaced belt conveyors; an interval passage for the first flipping hand to rotate through is provided between adjacent belt conveyors.

5. The fully automated production system for PCCP socket and spigot joints according to claim 4, characterized in that: A plurality of 90-degree flipping rollers hinged to the side of the roller conveyor line are located at the end of the corresponding interval passage.

6. A fully automated production process for PCCP socket and spigot joints, characterized in that using the fully automated production system for PCCP socket and spigot joints according to claim 4 or 5: includes the following steps: The first step is to operate the lifting equipment to hoist the socket and spigot sheet material into the storage rack and place it on the sheet material support; The second step is that the motor drives the first through shaft to rotate. After the first electromagnet on the first flipping hand adheres to the highest-end socket and spigot sheet material, start the first electromagnet to work and fix the highest-end socket and spigot sheet material; the motor drives the first through shaft to rotate in the reverse direction, the first flipping hand rotates to the interval passage, the socket and spigot sheet material is placed on the belt conveyor line, and stop the first electromagnet from working; In the third step, the socket and spigot sheet material is transported along the belt conveyor line. The front and back sides of the raw material are identified by the vision recognition device. When it is identified as the front side, it is transported normally, and the second flipping hand rotates to its original position. When it is identified as the back side, the second flipping hand rotates to the upper part of the upper end surface of the belt conveyor line along with the second through shaft, and the second electromagnet is activated to adsorb and fix the socket and spigot sheet material on the back side. The motor drives the second through shaft to rotate by 180 degrees, and the second flipping hand rotates to the lower part of the upper end surface of the belt conveyor line. After the socket and spigot sheet material is turned over in the air, it still falls onto the belt conveyor line and continues to be transported downward. In the fourth step, after the socket and spigot sheet material is erected by the 90-degree flipping roller, it is pushed into the rolling machine through the cooperation of the 90-degree flipping roller and the roller conveyor line. In the fifth step, the socket and spigot sheet material is rolled into a socket and spigot steel ring and rotates to the set working station. At this time, the internal and external welds are directly welded by the welding machine.

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