Double-block sleeper intelligent stirrup production line and control method thereof

Abstract

The embodiment of the application provides a double-block sleeper intelligent stirrup production line and a control method thereof. The stirrup production line comprises: a semi-finished product manufacturing mechanism; a semi-finished product conveying mechanism; a welding mechanism; a finished product conveying mechanism; a detection mechanism for detecting the stirrup finished product conveyed by the finished product conveying mechanism, judging whether the stirrup finished product is qualified or not, and distinguishing qualified products and unqualified products; a classification mechanism for transmitting the qualified product and unqualified product information to a PLC control center, and issuing an instruction from the PLC control center to the classification mechanism, placing the qualified products in a set qualified area and placing the unqualified products in a set unqualified area, and realizing the zoning storage of the qualified products and the unqualified products. The embodiment of the application replaces the traditional sampling inspection mode with a full inspection mode, reduces the quality inspection personnel, greatly improves the quality guarantee of each technical index of the stirrup, and solves the quality problems of incomplete welding and steel bar scald caused by manual welding.

Description

Technical Field

[0001] The embodiments of this application belong to the field of stirrup production technology, and in particular relate to a double-block intelligent stirrup production line for railway sleepers and its control method. Background Technology

[0002] In the production process of double-block sleepers, stirrups are an important component to ensure the internal strength of the double-block sleepers. Each double-block sleeper contains two stirrups. As an internal concealed project, the quality control of stirrups is particularly important.

[0003] In traditional production processes, the production mode generally involves mechanical bending of hoops combined with manual welding, while quality inspection is carried out through manual sampling.

[0004] This production process has many problems, including large personnel investment, high labor intensity, long working hours, uncontrollable quality, and occupational health hazards to construction workers. Summary of the Invention

[0005] The purpose of this application is to provide a dual-block intelligent stirrup production line for railway sleepers and its control method. By adding a testing mechanism, a full inspection method is used to replace the traditional sampling inspection method, which reduces the number of quality inspectors and greatly improves the quality assurance of various technical indicators of stirrups. It solves the quality problems such as incomplete welding and rebar burns caused by manual welding, greatly reduces human interference factors, and thus solves the problems in the background art.

[0006] To address the aforementioned technical problems, the technical solution for the dual-block intelligent stirrup production line for railway sleepers provided in this application is as follows:

[0007] This application discloses a dual-block intelligent stirrup production line for railway sleepers, comprising:

[0008] The semi-finished product manufacturing mechanism is used to bend cold-rolled steel bars into semi-finished stirrups to be welded, and to send the bent semi-finished stirrups to be welded out from the discharge port.

[0009] A semi-finished product transport mechanism is used to receive the semi-finished stirrups to be welded from the discharge port, and to transport the semi-finished stirrups to be welded from the discharge port using the stirrup clamps on the semi-finished product transport mechanism.

[0010] A welding mechanism is used to weld the semi-finished stirrups to be welded into finished stirrups;

[0011] A finished product transport mechanism is used to transport the finished stirrups welded by the welding mechanism.

[0012] The testing agency is used to test the finished stirrups transported by the finished product transportation agency, to determine whether the finished stirrups are qualified, to distinguish between qualified and unqualified products, and to realize the quality testing of stirrups.

[0013] The sorting mechanism is used to transmit the information of qualified and unqualified products to the PLC control center based on the distinction made by the testing agency. The PLC control center then issues instructions to the sorting mechanism to place qualified products in the designated qualified area and unqualified products in the designated unqualified area, thus realizing the separate placement of qualified and unqualified products.

[0014] In a preferred embodiment of any of the above solutions, the welding mechanism includes:

[0015] A welding positioning mechanism is used to place the semi-finished stirrup to be welded at the welding position;

[0016] The long-side positioning mechanism is used to push the semi-finished stirrup to be welded to the fixed blocking point on the welding side and lock it in place, thereby determining the position of the long side of the semi-finished stirrup to be welded.

[0017] The short-side positioning mechanism is used to determine the position of the short side of the semi-finished stirrup to be welded;

[0018] A spinning and positioning mechanism is used to shape the semi-finished stirrup to be welded.

[0019] In a preferred embodiment of any of the above solutions, the testing mechanism includes:

[0020] The imaging mechanism installed on the upper side of the testing mechanism is used to take pictures of the finished stirrups transported by the finished product transport mechanism.

[0021] The laser measuring mechanism installed on the upper side of the detection mechanism is used to detect the laser reflection intensity of the finished stirrups transported by the finished product transport mechanism;

[0022] A computer is used to receive images of the finished stirrups taken by the imaging mechanism and laser reflection intensity detected by the laser measurement mechanism, and to analyze the images and laser reflection intensity of the finished stirrups to determine whether the finished stirrups are qualified.

[0023] In a preferred embodiment of any of the above solutions, the stirrup production line further includes:

[0024] The control cabinet is electrically connected to the semi-finished product manufacturing mechanism, the semi-finished product transportation mechanism, the welding mechanism, the finished product transportation mechanism, and the testing mechanism, respectively.

[0025] In a preferred embodiment of any of the above schemes, an air valve is provided at the bottom of the welding positioning mechanism and the spinning positioning mechanism, and the air valve is connected to an external air compressor.

[0026] Compared with the prior art, the dual-block intelligent stirrup production line for railway sleepers in this application embodiment, by adding a testing mechanism, replaces the traditional sampling inspection method with a full inspection method, reduces the number of quality inspectors, and greatly improves the quality assurance of various technical indicators of stirrups. It solves the quality problems such as incomplete welding and rebar burns caused by manual welding, greatly reduces human interference factors, reduces safety hazards, and eliminates occupational health hazards for construction workers.

[0027] Secondly, a control method for a dual-block intelligent stirrup production line for railway sleepers, the control method comprising the following steps:

[0028] Real-time acquisition of information on the semi-finished stirrups to be welded manufactured by the semi-finished product manufacturing mechanism;

[0029] Based on the information of the semi-finished stirrup to be welded, a transportation instruction is sent to the semi-finished product transportation mechanism, and the location of the semi-finished product to be welded transported by the semi-finished product transportation mechanism is obtained;

[0030] The system receives the location where the semi-finished product transport mechanism transports the semi-finished stirrup to be welded, and issues a welding instruction to the welding mechanism to weld it into a finished stirrup.

[0031] Obtain the finished stirrup information welded by the welding mechanism, and send a finished stirrup transportation instruction to the finished product transportation mechanism based on the finished stirrup information;

[0032] Receive the finished stirrup transportation information, and send a finished stirrup inspection instruction to the inspection agency based on the finished stirrup transportation information;

[0033] The system receives the finished stirrup inspection information and sends a finished stirrup classification instruction to the classification agency.

[0034] In a preferred embodiment of any of the above solutions, the step of receiving the location where the semi-finished product transport mechanism transports the semi-finished stirrup to be welded, and issuing a welding instruction to the welding mechanism to weld it into a finished stirrup, specifically includes the following steps:

[0035] A first instruction is issued to the spinning positioning mechanism. The first instruction specifically includes: the rotating pressure plate at the top of the spinning positioning mechanism rotates from the initial position in the side direction to the upper side of the semi-finished hoop to be welded; and the telescopic cylinder at the bottom of the spinning positioning mechanism retracts to press the semi-finished hoop to be welded tightly.

[0036] Obtain the welding working surface of the semi-finished welded stirrup;

[0037] A second instruction is issued to the welding positioning mechanism, the second instruction including: the welding positioning mechanism makes directional movement on the guide rail, and the welding head starts welding from the fixed initial position and ends welding at the welding stop position;

[0038] A third instruction is issued to the spinning positioning mechanism, which includes: after welding is completed, the spinning positioning mechanism rises, the rotating pressure plate on the upper part of the spinning positioning mechanism rotates back to its initial position, and the short side positioning mechanism and the long side positioning mechanism retract.

[0039] In a preferred embodiment of any of the above solutions, sending the finished stirrup inspection instruction to the inspection agency specifically includes the following steps:

[0040] The shooting mechanism is instructed to take pictures of the finished stirrups transported by the finished product transportation mechanism;

[0041] And issue an instruction to the laser measuring mechanism to detect the laser reflection intensity of the finished stirrups transported by the finished product transport mechanism;

[0042] The computer receives information indicating whether the finished stirrups are qualified, based on the finished stirrup image and laser reflection intensity.

[0043] In a preferred embodiment of any of the above solutions, determining whether the finished stirrups are qualified specifically includes the following steps:

[0044] The point cloud of the photographed finished stirrup is obtained by acquiring the image of the finished stirrup taken by the shooting mechanism and the laser reflection intensity of the finished stirrup detected by the laser measuring mechanism.

[0045] Based on the point cloud of the photographed finished stirrups, a three-dimensional coordinate system is established with the X-axis, Y-axis and Z-axis corresponding to the stirrup placement surface, laser reflection intensity and color information, respectively, and a 3D model is formed.

[0046] Identify the location of the weld seam in the finished stirrup and convert the pixel coordinates in the three-dimensional coordinate system into actual length measurement units;

[0047] The length of the stirrup weld in the X-axis and Y-axis plane coordinate system is compared with the input standard value. If the length of the stirrup weld in the X-axis and Y-axis plane coordinate system is greater than the input standard value, then this indicator is qualified. If the length of the stirrup weld in the X-axis and Y-axis plane coordinate system is less than the standard value, then this indicator is unqualified.

[0048] The thickness of the stirrup weld is measured in the X-axis and Y-axis plane coordinate system and compared with the input standard value. If the actual thickness is greater than the standard value, the stirrup weld thickness index is qualified; if the actual thickness is less than the standard value, the stirrup weld thickness index is unqualified.

[0049] In a preferred embodiment of any of the above solutions, the determination of whether the finished stirrups are qualified further includes the following steps:

[0050] Length transformation is performed on the length, width, and length of the stirrup ends in the X-axis and Y-axis plane coordinate systems;

[0051] The length conversion value is compared with the error value of the input drawing index;

[0052] If it is within the error range, it is qualified; if it is outside the error range, it is unqualified.

[0053] Compared with the prior art, the dual-block intelligent stirrup production line for railway sleepers in this application embodiment, by adding a testing mechanism, replaces the traditional sampling inspection method with a full inspection method, reduces the number of quality inspectors, and greatly improves the quality assurance of various technical indicators of stirrups. It solves the quality problems such as incomplete welding and rebar burns caused by manual welding, greatly reduces human interference factors, reduces safety hazards, and eliminates occupational health hazards for construction workers. Attached Figure Description

[0054] The accompanying drawings, which are provided to further illustrate this application and constitute a component of it, are used to explain the application and do not constitute an undue limitation thereof. Some specific embodiments of the application will be described in detail below with reference to the accompanying drawings in an exemplary and non-limiting manner. The same reference numerals in the drawings denote the same or similar components or parts. It should be understood by those skilled in the art that these drawings are not necessarily drawn to scale.

[0055] Figure 1 This is a schematic diagram of the overall production line for the dual-block sleeper intelligent stirrups according to an embodiment of this application.

[0056] Figure 2 This is a flowchart illustrating the control method of the dual-block sleeper intelligent stirrup production line according to an embodiment of this application.

[0057] Figure 3 This is a schematic diagram illustrating the process of receiving the semi-finished product transport mechanism's transport position of the semi-finished stirrup to be welded and issuing a welding instruction to the welding mechanism to produce the finished stirrup, as described in the control method of the dual-block sleeper intelligent stirrup production line of this application.

[0058] Figure 4 This is a schematic diagram illustrating the process of sending a stirrup finished product inspection instruction to the inspection agency in the control method of the dual-block sleeper intelligent stirrup production line according to an embodiment of this application.

[0059] Figure 5 This is a schematic diagram illustrating the process of determining whether the finished stirrups are qualified in the control method of the intelligent stirrup production line for double-block sleepers according to an embodiment of this application.

[0060] Figure 6 This is another schematic diagram illustrating the process of determining whether the finished stirrups are qualified in the control method of the intelligent stirrup production line for double-block sleepers according to an embodiment of this application. Detailed Implementation

[0061] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are merely embodiments of one component of the present application, and not embodiments of the entire application. All other embodiments obtained by those skilled in the art based on the embodiments of the present application without creative effort should fall within the scope of protection of the present application.

[0062] It should be noted that when a component is referred to as being "fixed to" or "set on" another component, it can be directly on or indirectly on that other component. When a component is referred to as being "connected to" another component, it can be directly connected to or indirectly connected to that other component.

[0063] In the description of this application, it should be understood that the terms "length", "width", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and are not intended to indicate or imply that the mechanism or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention.

[0064] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0065] The following embodiments of this application use a dual-block intelligent stirrup production line for railway sleepers and its control method as an example to illustrate the solution of this application in detail. However, this embodiment does not limit the scope of protection of this application. Example

[0066] like Figure 1 As shown in the figure, this application provides a dual-block intelligent stirrup production line for railway sleepers, comprising:

[0067] The semi-finished product manufacturing mechanism 1 is used to bend cold-rolled steel bars into semi-finished stirrups to be welded, and to send the bent semi-finished stirrups to be welded out from the discharge port 11.

[0068] The semi-finished product transport mechanism 2 is used to receive the semi-finished stirrups to be welded from the discharge port 11, and transport the semi-finished stirrups to be welded from the discharge port 11 through the stirrup clamp 21 on the semi-finished product transport mechanism 2.

[0069] Welding mechanism 4 is used to weld the semi-finished stirrup to be welded into a finished stirrup;

[0070] Finished product transport mechanism 3 is used to transport the finished stirrups welded by the welding mechanism 4;

[0071] The testing agency 5 is used to test the finished stirrups transported by the finished product transport agency 3, to determine whether the finished stirrups are qualified, so as to distinguish between qualified and unqualified products and realize the quality testing of stirrups.

[0072] The sorting mechanism 6 is used to classify qualified and unqualified products according to the distinction made by the testing mechanism 5. It transmits the information of qualified and unqualified products to the PLC control center. The PLC control center issues instructions to the sorting mechanism 6 to place qualified products in the set qualified area and unqualified products in the set unqualified area, thereby realizing the separate stacking of qualified and unqualified products.

[0073] In the dual-block intelligent stirrup production line for railway sleepers described in this embodiment of the invention, by adding a testing mechanism, a full inspection method is used instead of the traditional sampling inspection method. This reduces the number of quality inspectors while greatly improving the quality assurance of various technical indicators of the stirrups. It solves quality problems such as incomplete welding and rebar burns caused by manual welding, greatly reduces human interference factors, reduces safety hazards, and eliminates occupational health hazards for construction workers. In this embodiment of the invention, the semi-finished product manufacturing mechanism 1 specifically refers to rebar straightening, shearing, and bending equipment, used to bend cold-rolled rebars into semi-finished stirrups to be welded; the semi-finished product transportation mechanism 2 specifically refers to a stirrup semi-finished product handling robot, used to transport the bent semi-finished stirrups to be welded to the welding structure; the welding... Mechanism 4 is located at a fixed platform. The finished product transport structure 3 specifically refers to a three-axis finished product handling robot that transports the welded stirrups from welding mechanism 4 to inspection mechanism 5, thus linking the intermediate links. The inspection machine 5 is used to inspect the processed stirrups and compare them with the allowable error range of various indicators in the technical specifications and drawings, distinguishing between qualified and unqualified products, and realizing the quality inspection of stirrups. The classification mechanism 6 specifically refers to a finished product classification and stacking robot. After the computer completes the analysis of qualified products, it transmits the information to the PLC control center. The PLC control center issues instructions to the stacking robot to place qualified products in the set qualified area and unqualified products in the set unqualified area, realizing the separate stacking of qualified and unqualified products.

[0074] like Figure 1 As shown, the welding mechanism 4 includes:

[0075] Welding positioning mechanism 43 is used to place the semi-finished stirrup to be welded at the welding position;

[0076] The long-side positioning mechanism 45 is used to push the semi-finished stirrup to be welded to the fixed blocking point on the welding side and lock it in place, thereby determining the position of the long side of the semi-finished stirrup to be welded.

[0077] Short side positioning mechanism 41 is used to determine the position of the short side of the semi-finished stirrup to be welded;

[0078] The spinning and positioning mechanism 42 is used to shape the semi-finished stirrup to be welded.

[0079] In the dual-block intelligent stirrup production line for railway sleepers described in this embodiment of the invention, the welding mechanism 4 is set up with two fixed positions. The welding mechanism 4 includes a long side positioning mechanism 45, a short side positioning mechanism 41, a spinning positioning mechanism 42, and a welding positioning mechanism 43. The welding positioning mechanism 43 is a directional welding robot. The long side positioning mechanism 45 and the short side positioning mechanism 41 are both telescopic cylinders. After the semi-finished stirrup is placed in the welding position, the long side positioning mechanism 45 operates, pushing the semi-finished stirrup to the fixed blocking point on the welding side and locking it in place. After determining the position of the long side of the stirrup (the left-right position is shown in the figure), the two telescopic cylinders of the short side positioning mechanism 41... The cylinder operates to determine the position of the short side of the stirrup (the position is shown in the vertical direction in the figure). After the position of the stirrup is determined, the spinning positioning mechanism 42 operates, and the upper rotating pressure plate rotates 90 degrees from the initial side position (not shown in the figure) to the upper side of the stirrup. At the same time, the bottom telescopic cylinder (not shown in the figure) retracts to press the semi-finished stirrup to be welded, and determines the contact area and flatness of the stirrup at the welding point. The welding robot makes directional movements on the guide rail 44, and the welding head starts welding from the fixed initial position to the welding stop position. After the welding is completed, the spinning positioning mechanism 42 rises, the upper rotating pressure plate rotates back to the initial position, and the short side positioning mechanism 41 and the long side positioning mechanism 45 retract, completing the overall welding process.

[0080] like Figure 1 As shown, the detection mechanism 5 includes:

[0081] The imaging mechanism 51 installed on the upper side of the detection mechanism 5 is used to take pictures of the finished stirrups transported by the finished product transport mechanism 3.

[0082] The laser measuring mechanism installed on the upper side of the detection mechanism 5 is used to detect the laser reflection intensity of the finished stirrups transported by the finished product transport mechanism 3.

[0083] A computer is used to receive images of the finished stirrups captured by the imaging mechanism 51 and laser reflection intensity detected by the laser measurement mechanism, and to analyze the images and laser reflection intensity of the finished stirrups to determine whether the finished stirrups are qualified.

[0084] In the dual-block intelligent stirrup production line for railway sleepers described in this embodiment of the invention, the detection mechanism 5 includes a camera 51 and a computer (not shown in the figure). The camera 51 is an industrial 3D camera, placed on top of the detection mechanism 5, to photograph the finished stirrups transported by the finished product transport mechanism 3. This equipment obtains the point cloud of the photographed finished stirrups through laser measurement and photogrammetry principles, establishing a three-dimensional coordinate system (X-axis, Y-axis, and Z-axis) based on the stirrup placement surface, laser reflection intensity, and color information. This allows for the formation of a 3D model in the computer system, while simultaneously identifying the stirrup weld positions. The computer program then converts the pixel coordinates within the coordinate system into actual length measurement sheets. The stirrup weld length is measured in the XY plane coordinate system and compared with the input standard value. If it is greater than the input standard value, the indicator is qualified; if it is less than the standard value, the indicator is unqualified. Similarly, the length of each part of the stirrup (end length, width, length) is converted and compared with the error value of the indicator in the input drawing. If it is within the error range, it is considered qualified; otherwise, it is unqualified. The stirrup weld thickness is measured in the X and Y plane coordinate systems and compared with the input standard value. If the actual thickness is greater than the standard value, the indicator is considered qualified; otherwise, the indicator is unqualified. If any of the above indicators is unqualified, the finished stirrup is considered unqualified. This is how qualified and unqualified products are distinguished, thus realizing the stirrup quality inspection.

[0085] like Figure 1 As shown, the stirrup production line also includes:

[0086] The control cabinet 7 is electrically connected to the semi-finished product manufacturing mechanism 1, the semi-finished product transportation mechanism 2, the welding mechanism 4, the finished product transportation mechanism 3, and the testing mechanism 5, respectively. The bottom of the welding positioning mechanism 4 and the spinning positioning mechanism 42 is equipped with air valves, which are connected to an external air compressor.

[0087] Compared with the prior art, the dual-block intelligent stirrup production line for railway sleepers in this application embodiment, by adding a testing mechanism, replaces the traditional sampling inspection method with a full inspection method, reduces the number of quality inspectors, and greatly improves the quality assurance of various technical indicators of stirrups. It solves the quality problems such as incomplete welding and rebar burns caused by manual welding, greatly reduces human interference factors, reduces safety hazards, and eliminates occupational health hazards for construction workers.

[0088] like Figure 2 As shown, in a second aspect, a control method for a dual-block intelligent railway sleeper stirrup production line includes the following steps:

[0089] Step 1: Obtain real-time information on the semi-finished stirrups to be welded manufactured by the semi-finished product manufacturing mechanism 1;

[0090] Step 2: Based on the information of the semi-finished stirrup to be welded, send a transportation instruction to the semi-finished product transportation mechanism 2, and obtain the location where the semi-finished product to be welded is transported by the semi-finished product transportation mechanism 2;

[0091] Step 3: Receive the location of the semi-finished stirrup to be welded transported by the semi-finished product transport mechanism 2, and issue a welding instruction to the welding mechanism 4 to weld it into a finished stirrup;

[0092] Step 4: Obtain the finished stirrup information welded by the welding mechanism 4, and send a finished stirrup transportation instruction to the finished product transportation mechanism 3 based on the finished stirrup information;

[0093] Step 5: Receive the finished stirrup transportation information, and send a finished stirrup inspection instruction to the inspection agency 5 based on the finished stirrup transportation information;

[0094] Step 6: Receive the finished stirrup inspection information and send the finished stirrup classification instruction to the classification mechanism 6.

[0095] In the dual-block intelligent stirrup production line for railway sleepers described in this embodiment of the invention, by adding a testing mechanism, the traditional sampling inspection method is replaced by a full inspection method, which reduces the number of quality inspectors and greatly improves the quality assurance of various technical indicators of the stirrups. It solves the quality problems such as incomplete welding and rebar burns caused by manual welding, greatly reduces human interference factors, reduces safety hazards, and eliminates occupational health hazards for construction workers.

[0096] like Figure 3 As shown, the step of receiving the semi-finished product transport mechanism 2 from the location where the semi-finished stirrup to be welded is transported, and issuing a welding instruction to the welding mechanism 4 to weld it into a finished stirrup, specifically includes the following steps:

[0097] Step 31: Issue a first instruction to the spinning positioning mechanism 42. The first instruction specifically includes: the rotating pressure plate on the upper part of the spinning positioning mechanism 42 rotates 90 degrees from the initial side position to the upper side of the semi-finished hoop to be welded, and the telescopic cylinder at the bottom of the spinning positioning mechanism 42 retracts to press the semi-finished hoop to be welded.

[0098] Step 32: Obtain the welding working surface of the semi-finished welded stirrup, where the contact area of ​​the weld and the flatness of the semi-finished product are guaranteed within this working surface;

[0099] Step 33: Issue a second instruction to the welding positioning mechanism 43. The second instruction includes: the welding positioning mechanism 43 moves in an orientation on the guide rail 44, and the welding head starts welding from the fixed initial position and ends at the welding stop position.

[0100] Step 34: Issue a third instruction to the spinning positioning mechanism 42 again. The third instruction includes: after welding is completed, the spinning positioning mechanism 42 rises, the rotating pressure plate on the upper part of the spinning positioning mechanism 42 rotates back to the initial position, and the short side positioning mechanism 41 and the long side positioning mechanism 45 retract.

[0101] In the dual-block intelligent stirrup production line for railway sleepers described in this embodiment of the invention, the welding mechanism 4 is set up with two fixed positions, specifically including a long side positioning mechanism 45, a short side positioning mechanism 41, a spinning positioning mechanism 42, and a welding positioning mechanism 43. In this embodiment of the invention, preferably, the welding positioning mechanism 43 is a welding robot that can move in a specific direction, and the long side positioning mechanism 45 and the short side positioning mechanism 41 are both telescopic cylinders. After the semi-finished stirrup is placed in the welding position, the long side positioning mechanism 45 operates, pushing the semi-finished stirrup to the fixed blocking point on the welding side and locking it in place. After determining the position of the long side of the stirrup ( Figure 1 (The inner position is in the left and right direction). The two telescopic cylinders of the short side positioning mechanism 41 operate to determine the position of the short side of the stirrup. Figure 1 (The inner part is the vertical position). After the position of the stirrup is determined, the spinning positioning mechanism 42 operates. The upper rotating pressure plate rotates 90 degrees from the initial side position (not shown in the figure) to the upper side of the stirrup. At the same time, the bottom telescopic oil cylinder (not shown in the figure) retracts to press the semi-finished stirrup to be welded, and determines the contact area and flatness of the stirrup at the welding point. The welding robot makes directional movements on the guide rail 44. The welding head starts welding from the fixed initial position and ends at the welding stop position. After the welding is completed, the spinning positioning mechanism 42 rises, the upper rotating pressure plate rotates back to the initial position, and the short side positioning mechanism 41 and the long side positioning mechanism 45 retract, and the overall welding process is completed.

[0102] like Figure 4 As shown, sending the stirrup finished product inspection instruction to the inspection agency 5 specifically includes the following steps:

[0103] Step 51: Issue an instruction to the photographing mechanism 51 to photograph the finished stirrups transported by the finished product transport mechanism 3;

[0104] Step 52: and issue an instruction to the laser measuring mechanism to detect the laser reflection intensity of the finished stirrups transported by the finished product transport mechanism 3;

[0105] Step 53: Receive information from the computer regarding whether the finished stirrups are qualified, based on the finished stirrup image and laser reflection intensity.

[0106] In the dual-block intelligent stirrup production line for railway sleepers described in this embodiment of the invention, the shooting mechanism 51 is an industrial 3D camera. After the computer completes the analysis of qualified products, it transmits the information to the PLC control center. The PLC control center sends instructions to the stacking robot to place qualified products in the set qualified area and unqualified products in the set unqualified area, thereby realizing the separate stacking of qualified and unqualified products.

[0107] like Figure 5 As shown, the process of determining whether a finished stirrup is qualified includes the following steps:

[0108] Step 531: Obtain the image of the finished stirrup captured by the shooting mechanism 51 and the laser reflection intensity of the finished stirrup detected by the laser measuring mechanism to obtain the point cloud of the photographed finished stirrup;

[0109] Step 532: Based on the point cloud of the photographed finished stirrup, establish a three-dimensional coordinate system with the X-axis, Y-axis and Z-axis corresponding to the stirrup placement surface, laser reflection intensity and color information respectively, and form a 3D model;

[0110] Step 533: Identify the location of the weld seam of the finished stirrup and convert the pixel coordinates in the three-dimensional coordinate system into actual length measurement units;

[0111] Step 534: Compare the measured length of the stirrup weld in the X-axis and Y-axis plane coordinate system with the input standard value. If the measured length of the stirrup weld in the X-axis and Y-axis plane coordinate system is greater than the input standard value, then this indicator is qualified. If the measured length of the stirrup weld in the X-axis and Y-axis plane coordinate system is less than the standard value, then this indicator is unqualified.

[0112] Step 535: Measure the thickness of the stirrup weld in the X-axis and Y-axis plane coordinate system and compare it with the input standard value. If the actual thickness is greater than the standard value, the stirrup weld thickness index is qualified; if the actual thickness is less than the standard value, the stirrup weld thickness index is unqualified.

[0113] like Figure 6 As shown, the determination of whether the finished stirrups are qualified also includes the following steps:

[0114] Step 5341: Perform length transformation on the length, width, and length of the stirrup ends in the X-axis and Y-axis plane coordinate systems;

[0115] Step 5342: Compare the length conversion value with the error value of the input drawing index;

[0116] Step 5343: If within the error range, it is qualified; if outside the error range, it is unqualified.

[0117] In the dual-block intelligent stirrup production line for railway sleepers described in this embodiment of the invention, the imaging mechanism 51 is an industrial 3D camera. The industrial 3D camera is placed on top of the detection mechanism 5 to photograph the finished stirrups transported by the finished product transport mechanism 3. This equipment obtains the point cloud of the photographed finished stirrups through the principles of laser measurement and photogrammetry, establishing a three-dimensional coordinate system (X-axis, Y-axis, and Z-axis) based on the stirrup placement surface, laser reflection intensity, and color information. A 3D model can be formed in the computer system, and the location of the stirrup weld can be identified. The computer program converts the pixel coordinates within the coordinate system into actual length measurement units. This allows for the measurement of the stirrups within the XY plane coordinate system. The length of the weld is measured and compared with the input standard value. If it is greater than the input standard value, the indicator is qualified; if it is less than the standard value, the indicator is unqualified. Similarly, the length of each part of the stirrup (end length, width, length) is converted and compared with the error value of the indicator in the input drawing. If it is within the error range, it is considered qualified; otherwise, it is unqualified. The thickness of the stirrup weld is measured in the X-axis and Y-axis plane coordinate system and compared with the input standard value. If the actual thickness is greater than the standard value, the indicator is considered qualified; otherwise, the indicator is unqualified. If any of the above indicators is unqualified, the finished stirrup is considered unqualified. This is how qualified and unqualified products are distinguished, and the quality inspection of the stirrup is realized.

[0118] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to the component or whole component technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A control method of a double-block sleeper intelligent stirrup production line, characterized by, The double-block sleeper intelligent stirrup production line comprises: A semi-finished product manufacturing mechanism (1) for bending cold-rolled steel bars into semi-finished products of stirrups to be welded and sending the bent semi-finished products of stirrups to be welded out of a discharge port (11); A semi-finished product conveying mechanism (2) for receiving the semi-finished products of stirrups to be welded sent out of the discharge port (11) and conveying the semi-finished products of stirrups to be welded received from the discharge port (11) through stirrup clamps (21) on the semi-finished product conveying mechanism (2); A welding mechanism (4) for welding the semi-finished products of stirrups to be welded into finished products of stirrups; A finished product conveying mechanism (3) for conveying the finished products of stirrups welded by the welding mechanism (4); A detection mechanism (5) for detecting the finished products of stirrups conveyed by the finished product conveying mechanism (3) to determine whether the finished products of stirrups are qualified or not, so as to distinguish qualified products from unqualified products and realize quality detection of the stirrups; A classification mechanism (6) for transmitting information of the qualified products and the unqualified products to a PLC control center according to the distinction of the qualified products and the unqualified products by the detection mechanism (5), and issuing an instruction from the PLC control center to the classification mechanism (6) to place the qualified products in a set qualified area and the unqualified products in a set unqualified area, so as to realize zoning and stacking of the qualified products and the unqualified products; The detection mechanism (5) comprises: A shooting mechanism (51) installed on the upper side of the detection mechanism (5) for shooting the finished products of stirrups conveyed by the finished product conveying mechanism (3); A laser measuring mechanism installed on the upper side of the detection mechanism (5) for detecting laser reflection intensity of the finished products of stirrups conveyed by the finished product conveying mechanism (3); A computer for receiving pictures of the finished products of stirrups shot by the shooting mechanism (51) and laser reflection intensity detected by the laser measuring mechanism, and analyzing the pictures of the finished products of stirrups and the laser reflection intensity to determine whether the finished products of stirrups are qualified or not; The control method comprises the following steps: Real-time acquisition of semi-finished product information of stirrups to be welded manufactured by the semi-finished product manufacturing mechanism (1); Sending of a conveying instruction to the semi-finished product conveying mechanism (2) according to the semi-finished product information of stirrups to be welded, and acquisition of a position of the semi-finished product conveying mechanism (2) for conveying the semi-finished products of stirrups to be welded; Receiving of the position of the semi-finished product conveying mechanism (2) for conveying the semi-finished products of stirrups to be welded, and issuing of a welding finished product of stirrups instruction to the welding mechanism (4); Acquisition of finished product information of stirrups welded by the welding mechanism (4), and sending of a conveying finished product of stirrups instruction to the finished product conveying mechanism (3) according to the finished product information of stirrups; Receiving of the conveying information of the finished product of stirrups, and sending of a finished product of stirrups detection instruction to the detection mechanism (5) according to the conveying information of the finished product of stirrups; Receiving of the finished product of stirrups detection information, and sending of a finished product of stirrups classification instruction to the classification mechanism (6); The sending of the finished product of stirrups detection instruction to the detection mechanism (5) specifically comprises the following steps: Issuing of an instruction to the shooting mechanism (51) to shoot the finished products of stirrups conveyed by the finished product conveying mechanism (3). And issue an instruction to the laser measuring mechanism to detect the laser reflection intensity of the finished stirrups transported by the finished product transport mechanism (3); Receive information from the computer regarding whether the finished stirrups are qualified, based on the finished stirrup image and laser reflection intensity. The determination of whether the finished stirrups are qualified includes the following steps: The image of the finished stirrup captured by the shooting mechanism (51) and the laser reflection intensity of the finished stirrup detected by the laser measuring mechanism are obtained to obtain the point cloud of the photographed finished stirrup. Based on the point cloud of the photographed finished stirrups, a three-dimensional coordinate system is established with the X-axis, Y-axis and Z-axis corresponding to the stirrup placement surface, laser reflection intensity and color information, respectively, and a 3D model is formed. Identify the location of the weld seam in the finished stirrup and convert the pixel coordinates in the three-dimensional coordinate system into actual length measurement units; The length of the stirrup weld in the X-axis and Y-axis plane coordinate system is compared with the input standard value. If the length of the stirrup weld in the X-axis and Y-axis plane coordinate system is greater than the input standard value, then this indicator is qualified. If the length of the stirrup weld in the X-axis and Y-axis plane coordinate system is less than the standard value, then this indicator is unqualified. The thickness of the stirrup weld in the X-axis and Y-axis plane coordinate system is measured and compared with the input standard value. If the actual thickness is greater than the standard value, the stirrup weld thickness index is qualified; if the actual thickness is less than the standard value, the stirrup weld thickness index is unqualified. Length transformation is performed on the length, width, and length of the stirrup ends in the X-axis and Y-axis plane coordinate systems; The length conversion value is compared with the error value of the input drawing index; If it is within the error range, it is qualified; if it is outside the error range, it is unqualified.

2. The control method of the double-block sleeper intelligent stirrup production line according to claim 1, characterized in that, The welding mechanism (4) includes: A welding positioning mechanism (43) is used to place the semi-finished stirrup to be welded at the welding position; The long side positioning mechanism (45) is used to push the semi-finished stirrup to be welded to the fixed blocking point on the welding side and lock it in place, thereby determining the position of the long side of the semi-finished stirrup to be welded. Short side positioning mechanism (41) is used to determine the position of the short side of the semi-finished stirrup to be welded; The spinning positioning mechanism (42) is used to shape the semi-finished stirrup to be welded.

3. The control method of the double-block sleeper intelligent stirrup production line according to claim 1, characterized in that, The stirrup production line also includes: The control cabinet (7) is electrically connected to the semi-finished product manufacturing mechanism (1), the semi-finished product transportation mechanism (2), the welding mechanism (4), the finished product transportation mechanism (3), and the testing mechanism (5), respectively.

4. The control method of the double-block sleeper intelligent stirrup production line according to claim 2, characterized in that, The welding positioning mechanism and the spinning positioning mechanism are equipped with air valves at their bottoms, and the air valves are connected to an external air compressor.

5. The control method of the double-block sleeper intelligent stirrup production line according to claim 2, characterized in that, The receiving semi-finished product transport mechanism (2) transports the semi-finished stirrup to be welded to the location, and issues a welding instruction to the welding mechanism (4) to weld it into a finished stirrup. The specific steps include: A first instruction is issued to the spinning positioning mechanism (42), the first instruction specifically includes: the rotating pressure plate on the upper part of the spinning positioning mechanism (42) rotates 90 degrees from the initial position on the side to the upper side of the semi-finished hoop to be welded, and the telescopic cylinder at the bottom of the spinning positioning mechanism (42) retracts to press the semi-finished hoop to be welded tightly; Obtain the welding working surface of the semi-finished welded stirrup; A second instruction is issued to the welding positioning mechanism (43), the second instruction including: the welding positioning mechanism (43) makes directional movement on the guide rail (44), and the welding head starts welding from the fixed initial position to the welding stop position; A third instruction is issued to the spinning positioning mechanism (42) again. The third instruction includes: after welding is completed, the spinning positioning mechanism (42) rises, the rotating pressure plate on the upper part of the spinning positioning mechanism (42) rotates back to the initial position, and the short side positioning mechanism (41) and the long side positioning mechanism (45) retract.

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