Intelligent Tensioning Control Method and Intelligent Tensioning Robot

Abstract

An intelligent tensioning control method and an intelligent tensioning robot. Through the XYZA four-axis positioning control system, a laser rangefinder is fixed on the jack to measure the distance to the limit plate. The light point of the laser rangefinder is automatically offset upward and downward, and the laser ranging displacements of the upper point and the lower point are recorded. The four-axis positioning system automatically calculates the angle of the cross-section of the jack relative to the cross-section of the limit plate, and automatically adjusts the angle between the cross-section of the jack and the limit plate to make them parallel. The radius R of the limit plate is determined by using the three-point coordinates of the edge of the limit plate. After determining the center of the limit plate, the forward movement distance is calculated and the jack is automatically moved forward to the position of the hole to be tensioned. After completing the installation of one beam hole, the installation of the next hole is automatically carried out. Its advantages are that it can achieve automatic alignment, automatic threading of steel strands, automatic tensioning, and complete the tensioning work of the entire beam at one time for different beam working conditions, saving manual operation time and having high efficiency.

Description

Technical Field

[0001] The present invention relates to the field of tensioning technology for prestressed construction, and more specifically, to an intelligent tensioning control method and an intelligent tensioning robot. Background Art

[0002] In prestressed construction, it is necessary to pass steel strands between the jack assembly and the beam and perform tensioning. The construction method is to manually install the jack assembly at the front end of the beam, pass the hinge strands, and then perform tensioning. These constructions require a large amount of manual operations and continuous disassembly and assembly of equipment, which are time-consuming, laborious, and inefficient. Summary of the Invention

[0003] The purpose of the present invention is to provide an intelligent tensioning control method and an intelligent tensioning robot that can automatically align, automatically pass steel strands, automatically perform tensioning, and complete the tensioning work of the entire beam at one time for different beam conditions.

[0004] The technical solution disclosed by the present invention is:

[0005] An intelligent tensioning control method includes the following steps:

[0006] (1) Four-axis positioning mechanism setting step: Two X, Y, Z moving mechanisms are established side by side. A rotating mechanism A is respectively arranged at the output end of each X, Y, Z moving mechanism to establish an XYZA four-axis positioning control system. The jack is connected to the four-axis positioning control system, and a laser rangefinder is fixed on the jack;

[0007] (2) Step of positioning the horizontal distance between the positioning trolley and the tensioning beam hole: Move the XYZA four-axis positioning system to one side of the beam. The laser rangefinder measures the relative distances L1 and L2 between the two ends of the tensioning beam, and ensure that │L1 - L2│≤5mm;

[0008] (3) Step of the four-axis positioning system positioning the tensioning beam hole: Manually adjust the laser spot of the laser rangefinder to the initial position point of the laser point of the AA hole limit plate of the tensioning beam and the second position point B for measuring the angle. Operate the touch screen of the four-axis positioning control system to read and store the current absolute position data of the X-axis, Y-axis, Z-axis, and A-axis of the four-axis positioning control system. Set the X and Y axis coordinates to (0, 0), and then input the drawing sizes of each hole to calculate the coordinates of the remaining holes;

[0009] (4) Step of determining the initial position point of the limit plate laser point and the second position point B for measuring the angle: The setting rules for the initial position point of the laser point and the second position point B for measuring the angle are that the horizontal and vertical movement paths shall not intersect with the holes of the limit plate. The initial position point of the laser point and the second position point B for measuring the angle are set at any one of the lower right corner, upper right corner, upper left corner, or lower left corner:

[0010] (5)Steps for operating to download the initial coordinate position of the hole to be tensioned: Select the hole to be tensioned through the previous hole or next hole button. The XYZA four-axis positioning system automatically positions the initial coordinate position. After all the tensioning holes are positioned and recorded, download the initial coordinate parameters into the PLC controller;

[0011] (6)Steps for measuring the angle of the limit plate: Control the four-axis positioning system to automatically shift the laser beam of the laser rangefinder upward and downward, record the laser ranging displacements at the upper point and the lower point, and the four-axis positioning system automatically calculates the angle of the cross-section of the jack relative to the cross-section of the limit plate:

[0012] (7)Steps for adjusting the angle of the jack: At this time, the laser beam of the laser rangefinder has left the initial position point of the laser point and the second position point B for measuring the angle. Through calculation, automatically adjust the laser beam of the laser rangefinder back to the initial position point of the laser point and the second position point B for measuring the angle;

[0013] (8)Steps for measuring the center of the limit plate: Automatically scan the contour edge of the limit plate through the laser rangefinder, automatically read three coordinates of the contour edge of the limit plate, and then automatically calculate the center coordinate of the limit plate and the radius R of the limit plate through the three measured coordinates; The four-axis positioning system automatically judges whether the calculated radius of the limit plate is consistent with the preset radius of the limit plate. If not, send it to the center counter for calculation, and then input to perform the operation of automatically reading three coordinates of the contour edge of the limit plate again. Repeat the above steps until the radius of the limit plate is consistent with the preset radius of the limit plate;

[0014] (9)According to the calculated center coordinates, add the distance between the laser instrument and the center of the jack to the y-axis coordinate value, and automatically move the jack to the position of the hole to be tensioned;

[0015] (10)Steps for the jack to move forward: The four-axis positioning system automatically moves forward along the steel strand direction according to the previously measured angle, calculates the forward movement distance according to the distance measured by the laser at the initial position point of the laser point and the second position point B for measuring the angle, and automatically moves forward to move the jack to the position of the hole to be tensioned.

[0016] As a preferred solution, in the step (3), the touch screen of the four-axis positioning control system reads the current absolute position data of the X-axis, Y-axis, Z-axis, and A-axis of the four-axis positioning control system as the initial position for the automatic control of the XYZA axes.

[0017] As a preferred solution, in the step (6), the calculation method adopted by the four-axis positioning system for automatically calculating the angle of the cross-section of the jack relative to the cross-section of the limit plate is: Angle A = ATAN (coordinate difference between two points on the Z-axis / ranging difference between two points on the Y-axis); The adjustment steps include:

[0018] 1) The XYZA servo system first moves the laser beam to the initial coordinate position;

[0019] 2) The XYZA servo system records the laser displacement with an upward offset and then with a downward offset, and calculates the angular deviation between the laser jack and the limit plate through trigonometric functions.

[0020] 3) The XYZA servo system automatically corrects the angles of the jack and the limit plate based on the calculated angular deviation to keep them parallel.

[0021] 4) The XYZA servo system compares the offset distance between the center of the limit plate calculated through trigonometric functions with the preset center of the jack in the system, and automatically corrects the centers of the jack and the limit plate to make them concentric.

[0022] As a preferred solution, in step (8), the method for setting the three coordinates of the contour edge of the limit plate is as follows: starting from the initial position coordinates, scan to the edge of the limit plate to the right, and automatically record and store the edge position coordinates 1 (X1, Y1); starting from the initial position coordinates, scan to the edge of the limit plate to the left, and automatically record and store the edge position coordinates 2 (X2, Y2); starting from the initial position coordinates, scan to the edge of the limit plate upward, and automatically record and store the edge position coordinates 3 (X3, Y3).

[0023] As a preferred solution, in step (8), the method for setting the three coordinates of the contour edge of the limit plate is measured by the laser displacement value jump change method, that is, a sudden step is set at the edge of the end face of the limit plate. The PLC reads the displacement value of the laser displacement sensor in real time through the MODBUS bus communication protocol. When it is monitored that the laser displacement is at the position of the sudden step and the laser displacement value jumps and changes by more than the preset value, the PLC determines that the edge position coordinates are set successfully and records and saves them.

[0024] An intelligent tensioning robot includes an XYZA four-axis positioning control system composed of X, Y, Z moving mechanisms and a rotating mechanism A, and a limit plate. The X, Y, Z moving mechanisms and the rotating mechanism A are installed on the walking system platform and move with the walking system. The jack assembly is connected to the four-axis positioning control system, and a laser rangefinder is fixed on the jack assembly. The laser rangefinder is used to measure the distance data between the jack assembly and the bridge and the data of the limit plate, and input the data into the XYZA four-axis positioning control system. The XYZA four-axis positioning control system is used to control the jack assembly to align with the position of the hole to be tensioned and send the jack into the hole to be tensioned.

[0025] As a preferred solution, the rotating mechanism A adopts a structure in which the Y-axis guide rail is pin-jointed with the rotating lifting frame to realize the rotation of the rotating lifting frame; the rotating lifting frame is provided with a rod end joint bearing supported by the spring force of the spring assembly, and the swinging end of the rod end joint bearing is connected to the jack assembly; the rotating lifting frame fixes the pressing head assembly, and the lower end of the pressing head assembly contacts the rear end of the jack assembly, offsetting the gravity of the front end of the jack to maintain the balance of the jack assembly.

[0026] As a preferred solution, the rotating mechanism A includes a top mounting bracket fixed to the Y-axis assembly, a rotating bracket, a rotating pin, a cam link, and an electric cylinder assembly; the rotating bracket is hinged to the top mounting bracket, one end of the rotating bracket is connected to the top mounting bracket through a spring assembly, and the other end of the rotating bracket is hinged to the jack assembly; the cam is connected and hinged to the rotating bracket, the middle of the cam link is connected to the electric cylinder assembly, and under the push of the electric cylinder assembly, the swinging of the cam assembly pushes the jack assembly to rotate.

[0027] As a preferred solution, the laser rangefinder is installed outside the jack assembly or on the piston of the jack assembly.

[0028] As a preferred solution, a step with a sudden change is provided at the edge of the end face of the limiting plate. When the laser rangefinder measures the position of this step, the edge position is judged by the sudden change of the laser displacement value.

[0029] The beneficial effects of the present invention are as follows: It can achieve automatic alignment, automatic threading of steel strands, automatic tensioning for different beam working conditions, and complete the tensioning work of the entire beam at one time, saving manual operation time and having high efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figures 1-1 to 1-4 is the control principle block diagram of the present invention.

[0031] Figure 2 is the structure schematic diagram of the intelligent robot of the present invention.

[0032] Figure 3 is the structure diagram of the first embodiment of the rotating mechanism A of the present invention.

[0033] Figure 4 is Figure 3 the structure diagram of the mechanism for releasing the downward degree of freedom of the jack shown.

[0034] Figure 5 is the structure diagram of the second embodiment of the rotating mechanism A of the present invention.

[0035] Figure 6 is Figure 5 the structure diagram of the mechanism for releasing the downward degree of freedom of the jack shown.

[0036] Figure 7It is the structural diagram of the XYZA four-axis positioning control system for movement.

[0037] Figure 8 It is Figure 7 the front view of.

[0038] Figure 9 It is Figure 8 the right view of.

[0039] Figure 10 It is the schematic diagram of the coordinates of the rough positioning tensioning holes for beam 31.

[0040] Figure 11 It is the schematic diagram of the laser rangefinder's light spot being measured at the lower right of the limit plate.

[0041] Figure 12 It is Figure 11 the schematic diagram of the position measured by the laser rangefinder for the limit plate at the location where it is located.

[0042] Figure 13 It is the schematic diagram of measuring the angle.

[0043] Figure 14 It is the schematic diagram of determining the relative distance in the rough positioning step of the four-axis positioning system.

[0044] Figure 15 It is the structural schematic diagram of the laser rangefinder installed on the piston of the jack assembly.

[0045] Figure 16 It is Figure 15 the front view when the laser rangefinder is working.

[0046] Figure 17 It is Figure 15 the front view when the laser rangefinder stops working.

[0047] Figure 18 It is the schematic diagram of the state when the steel strand is tensioned to the longest.

[0048] Figure 19 It is the structural schematic diagram of the limit plate 30 of the present invention.

[0049] Figure 20 It is the schematic diagram of the coordinates set for the limit plate 30.

[0050] Figure 21 It is the schematic diagram of the steps for adjusting the angle of the jack.

[0051] The parts list of the attached drawings are as follows: 1. Travel system, 2. X, Y, Z, A four-axis positioning system, 3. Tensioning system, 4. Control system, 5. Laser rangefinder, 6. Transverse base, 7. Electric cylinder rotating pin, 8. Electric cylinder assembly, 9. Rotating lifting frame, 10. Rotating lifting frame, 11. Jack assembly, 12. Rotating lifting frame pin, 13. Electric cylinder rotating pin, 14. First electric cylinder assembly, 15. Rotating bracket, 16. Camshaft, 17. Cam, 18. Cam connecting rod, 19. Jack rotating pin, 20. Cam contact plate, 21. Top mounting bracket, 101. Top mounting bracket, 102. Spring assembly, 103. Press head assembly, 104. First rod end joint bearing, 111. First top mounting bracket, 112. First spring assembly, 113. Rotating pin, 114. Jack rotating pin, 22. Z-axis moving base, 23. X-axis guide rail, 24. X-axis moving base, 25. Z-axis servo motor and reducer, 26. Z-axis rack, 27. Z-axis driving gear, 28. X-axis servo motor and reducer, 29. X-axis driving gear, 210. X-axis rack, 211. Y-axis guide rail, 212. Steel wheel, 213. Chain, 214. Chain guide wheel, 215. Y-axis servo motor and electric cylinder, 216. Z-axis guide rail, 30. Limit plate, 31. Beam, 32. Jack, 33. Mounting bracket, 34. Servo, 35. Steel strand, 36. Tool anchor assembly.

[0052] B, the initial position of the laser point and the second position for measuring the angle, C, the position coordinate 1 of the edge of the limit plate, D, the position coordinate 2 of the edge of the limit plate, E, the position coordinate 3 of the edge of the limit plate, F, the first position for measuring the angle. DETAILED DESCRIPTION

[0053] The present invention will be further described and illustrated below in conjunction with specific embodiments and accompanying drawings:

[0054] Please refer to Figure 1-1 , 1-2 , 1-3, will Figures 1-1 to 1-3 After being combined in sequence, the whole control principle block diagram of the present invention is obtained. The present invention comprises the steps:

[0055] (1) Steps for setting up the four-axis positioning mechanism: establish two X, Y, and Z moving mechanisms side by side, set up a rotating mechanism A at the output end of each X, Y, and Z moving mechanism, establish an XYZA four-axis positioning control system, connect the jack to the four-axis positioning control system, and fix the laser rangefinder on the jack;

[0056] (2) Steps for locating the horizontal distance between the trolley and the tension beam hole: Move the XYZA four-axis positioning system to one side of the beam, and use the laser rangefinder to measure the relative distances L1 and L2 between the two ends of the tension beam, and ensure that |L1-L2|≤5mm; see Figure 14 ;

[0057] (3)Steps for the four-axis positioning system to position the tension beam holes: Manually adjust the light spot of the laser rangefinder to the initial position point of the laser point on the limit plate of hole AA of the tension beam and the second position point B for measuring the angle. Operate the touch screen of the four-axis positioning control system to read and store the current absolute position data of the X-axis, Y-axis, Z-axis, and A-axis of the four-axis positioning control system. Set the X and Y axis coordinates to (0, 0), and then input the drawing dimensions of each hole to calculate the coordinates of the remaining holes; for the specific method, refer to Figure 10 , set the starting point as hole AA (other holes can also be set as the starting point). Manually adjust the position of the jack to the initial position point of the laser point on the limit plate of hole AA and the second position point B for measuring the angle, set the coordinates to (0, 0), then input the drawing dimensions of each hole, and automatically obtain the coordinates of the remaining holes. The positioning method for the right holes is the same as that for the left holes.

[0058] (4)Steps for determining the initial position point of the laser point on the limit plate and the second position point B for measuring the angle: The setting rules for the initial position point of the laser point and the second position point B for measuring the angle are that the horizontal and vertical movement paths shall not intersect with the holes of the limit plate. The initial position point of the laser point and the second position point B for measuring the angle are set at any one of the lower right corner, upper right corner, upper left corner, or lower left corner: refer to Figure 12 , in this embodiment, the lower right corner is used as the initial position point of the laser point and the second position point B for measuring the angle

[0059] (5)Steps for operating and downloading the initial coordinate positions of the holes to be tensioned: Select the hole to be tensioned through the previous hole or next hole button. The XYZA four-axis positioning system automatically positions the initial coordinate positions. After all the tension beam holes are positioned and recorded, download the initial coordinate parameters into the PLC controller. Refer to Figure 11 ;

[0060] (6)Steps for measuring the angle of the limit plate: Control the four-axis positioning system to automatically move the light spot of the laser rangefinder upward and downward, record the laser ranging displacements of the upper and lower points. The four-axis positioning system automatically calculates the angle of the cross-section of the jack relative to the cross-section of the limit plate: refer to Figure 12 , where the upper point is the first position point F for measuring the angle in the figure, and the lower point is the initial position point of the laser point and the second position point B for measuring the angle in the figure;

[0061] The four-axis positioning system automatically calculates the angle of the cross-section of the jack relative to the cross-section of the limit plate, and automatically adjusts the angles of the cross-section of the jack and the limit plate so that the distances between the upper and lower points of the light spot of the laser rangefinder are equal, and the cross-section of the jack and the limit plate are kept parallel. Refer to Figure 13 ,

[0062] (7)Steps to adjust the angle of the jack: At this time, the light spot of the laser rangefinder has left the initial position point of the laser point and the second position point B for angle measurement. Through calculation, the light spot of the laser rangefinder is automatically adjusted back to the initial position point of the laser point and the second position point B for angle measurement; see Figure 21 , the laser rangefinder emits laser from the laser head point 1A position to the initial position point of the laser point on the limit plate and the second position point B for angle measurement. Assuming the angle of the limit plate is 10 degrees and the jack rotates 10 degrees, the laser head rotates from the laser head point 1A position to the laser head point 2A position. At this time, the laser has left the initial position point of the laser point and the second position point B for angle measurement. To return to the initial point position, the laser head point 2A position needs to be moved up to the laser head point 3A position, and the distance L is moved up on the Y-axis coordinate.

[0063] (8)Steps to measure the center of the limit plate: The laser rangefinder automatically scans the contour edge of the limit plate, automatically reads three coordinates of the contour edge of the limit plate, and then uses the common center calculation formula to automatically calculate the center coordinates and radius R of the limit plate based on the three measured coordinates; the four-axis positioning system automatically determines whether the calculated radius of the limit plate is consistent with the preset radius of the limit plate. If not, it is sent to the center counter for calculation, and after calculation, it is input to automatically read the three coordinates of the contour edge of the limit plate again. Repeat the above steps until the radius of the limit plate is consistent with the preset radius of the limit plate;

[0064] (9)According to the calculated center coordinates, add the distance between the laser instrument and the top center to the y-axis coordinate value. Automatically move the jack to the position of the hole to be tensioned;

[0065] (10)Steps for the jack to move forward: The four-axis positioning system automatically moves forward along the steel strand direction according to the previously measured angle, calculates the forward movement distance based on the distance measured by the laser at the initial position point of the laser point and the second position point B for angle measurement, and automatically moves forward to move the jack to the position of the hole to be tensioned.

[0066] In the step (3) above, the touch screen of the four-axis positioning control system reads the current absolute position data of the X-axis, Y-axis, Z-axis, and A-axis of the four-axis positioning control system as the initial position for the automatic control of the XYZA axis.

[0067] In the step (6) above, the calculation method used by the four-axis positioning system to automatically calculate the angle of the cross-section of the jack relative to the cross-section of the limit plate is: Angle A = ATAN (coordinate difference between two points on the Z-axis / distance difference between two points on the Y-axis for distance measurement). The measurement method is shown in Figure 13 ;

[0068] Its adjustment steps include:

[0069] 1) The XYZA servo system first moves the laser light spot to the initial coordinate position, see Figure 11The initial position point of the laser spot and the second position point B for measuring the angle therein;

[0070] 2) The XYZA servo system records the laser displacement by upward offset and then by downward offset, and calculates the angle deviation between the laser jack and the limit plate through a trigonometric formula;

[0071] 3) The XYZA servo system automatically corrects the angles of the jack and the limit plate through the calculated angle deviation to keep them in a parallel state;

[0072] 4) The XYZA servo system compares the offset distance between the center of the limit plate calculated through a trigonometric formula with the preset center of the jack of the system, and automatically corrects the centers of the jack and the limit plate to keep them concentric.

[0073] In the said step (8), the method for setting the three coordinates of the contour edge of the limit plate is as follows: starting from the initial position coordinates, scan to the edge of the limit plate to the right, and automatically record and store the edge position coordinates 1 (X1, Y1); starting from the initial position coordinates, scan to the edge of the limit plate to the left, and automatically record and store the edge position coordinates 2 (X2, Y2); starting from the initial position coordinates, scan to the edge of the limit plate upwards, and automatically record and store the edge position coordinates 3 (X3, Y3), see Figure 12 wherein the three coordinates of the contour edge of the limit plate are respectively: the limit plate edge position coordinate 1C, the limit plate edge position coordinate 2D, and the limit plate edge position coordinate 3E.

[0074] In the said step (8), the method for setting the three coordinates of the contour edge of the limit plate is measured by the laser displacement value jump change method, that is, a sudden step is set at the edge of the end face of the limit plate, and the PLC reads the displacement value of the laser displacement sensor in real time through the MODBUS bus communication protocol. When it is monitored that the laser displacement is at the position of the sudden step and the laser displacement value jumps and changes by more than the preset value, the PLC judges that the edge position coordinate setting is successful, records and saves it, see Figure 19 、 20 In the present invention, the edge of the end face of the limit plate 30 is a stepped structure, forming a judgment point for the laser rangefinder to measure the sudden displacement jump value; taking Figure 19The numerical values are described as follows: Based on the traditional limit plate, a raised step is added at the back of the limit plate. The main purpose is to facilitate the laser rangefinder to effectively identify the jump in distance, thereby identifying the edge of the outer diameter, finding the edge coordinate positions at three different locations, and achieving the purpose of automatically detecting the center of the limit plate. Its working principle is as follows: Based on the traditional limit plate, a raised step is added. Generally, 5 - 10 mm needs to be added to the outer diameter on each side, and the depth is ≥ 20 mm. The laser rangefinder emits laser light and hits the initial point on the limit plate, and records the measured distance value. The laser moves horizontally. When the laser sweeps across the edge position coordinate 1, the increment of the laser range measurement is greater than the value set by the program, and the laser rangefinder stops advancing and records the coordinate value. For example: The set judgment value of the program is ≥ 15 mm, the initial point range measurement is 300 mm, when sweeping across the edge position coordinate 1, the range measurement is 320 mm, and the increment value is 20 mm, which meets the requirements of the judgment value, and the laser rangefinder stops advancing. Similarly, the coordinates of the edge position coordinates 2 and 3 are found in turn. With the three coordinate values, the center coordinate of the limit plate can be calculated.

[0075] Combined with the attached Figure 1-1 、 1-2 、1 - 3, 1 - 4, 2, 3, 4, 5, 6, 7, an embodiment of a system of the present invention is as follows:

[0076] This system is composed of a walking trolley system, an XYZA four-axis positioning control system, and an intelligent tensioning system.

[0077] After combining Figures 1-1 to 1-4 in sequence, it is the entire control principle block diagram of the present invention.

[0078] The walking system is responsible for moving the XYZA four-axis positioning system and the intelligent tensioning system to the vicinity of the bridge to be tensioned. The relative distances between the walking trolley and the two ends of the bridge are measured by the laser displacement sensors on both sides of the four-axis positioning system to ensure that the four-axis positioning control system maintains a parallel attitude relative to the bridge. At this time, the walking system props up the support feet to keep the intelligent tensioning robot system in a relatively static state relative to the tensioning beam.

[0079] When the intelligent tensioning jack needs to be automatically inserted into the tensioning hole, the XYZA four-axis positioning control system needs to perform the following steps of operations.

[0080] 1. Move the laser displacement sensor light spot to the lower right of the limit plate through the handheld remote control;

[0081] 2. Operate the touch screen of the four-axis positioning control system to read and store the current coordinates of the servo of the four-axis positioning control system.

[0082] 3. Repeat steps 1 and 2 for other tensioning holes to be tensioned. After all the tensioning holes are recorded, download the initial coordinate parameters into the PLC controller.

[0083] 4. Operate the "Previous Hole" or "Next Hole" button of the XYZA four-axis positioning system to select the hole to be tensioned.

[0084] 5. The XYZA four-axis positioning system automatically measures the angle of the limit plate through a laser displacement sensor.

[0085] 6. The XYZA four-axis positioning system automatically adjusts the angle between the cross-section of the jack and the limit plate to keep them parallel.

[0086] 7. The XYZA four-axis positioning system automatically scans the contour edge of the limit plate through a laser displacement sensor, automatically reads three coordinates of the contour edge of the limit plate, and then automatically calculates the center coordinates of the limit plate.

[0087] 8. The XYZA four-axis positioning system automatically calculates the offset distance between the center of the limit plate and the center of the jack.

[0088] 9. The XYZA four-axis positioning system automatically moves the jack to the position of the tensioning hole to be penetrated, and automatically adjusts the distance between the center of the jack and the center of the limit plate to keep them concentric.

[0089] 10. The XYZA four-axis positioning system automatically inserts the jack into the tensioning hole.

[0090] 11. The XYZA four-axis positioning system notifies the intelligent tensioning system to perform tensioning according to the preset tensioning process.

[0091] 12. After the intelligent tensioning system finishes tensioning, it notifies the XYZA four-axis positioning system that the tensioning is completed.

[0092] 13. The XYZA four-axis positioning system automatically withdraws the jack from the tensioning hole.

[0093] 14. If other holes need to be tensioned, return to step 4 through AB in Figure 1 and repeat the operation.

[0094] Based on the above basic method, the intelligent tensioning robot of the present invention includes an XYZA four-axis positioning control system composed of X, Y, Z moving mechanisms and a rotating mechanism A (such as Figure 7 , 8, as shown in Figure 9, a limit plate 30. The X, Y, Z moving mechanism and the rotating mechanism A are installed on the platform of the traveling system 1 and move along with the traveling system 1. The traveling system platform is installed with a tensioning system 3 and a control system 4. The tensioning system includes an oil tank and a hydraulic pump station, and the control system includes a PLC control center or a computer control center, thus forming an integrated whole. The jack assembly 11 is connected to the four-axis positioning control system. A laser rangefinder 5 is fixed on the jack assembly 11. The laser rangefinder 5 is used to measure the distance data between the jack 32 and the bridge 31 and the data of the limit plate 30, and input the data into the XYZA four-axis positioning control system. The XYZA four-axis positioning control system is used to control the jack 32 to align with the position of the hole to be tensioned and send the jack 32 into the hole to be tensioned. A sudden step is provided at the edge of the end face of the limit plate 30. When the laser rangefinder 5 measures the position of this step, the edge position is judged by the sudden change in the laser displacement value.

[0095] As Figure 19 , 20 shown, the edge of the end face of the limit plate 30 is a stepped structure, forming a judgment point for the laser rangefinder to measure the sudden displacement jump value. Taking Figure 19 the following numerical values as an example: on the basis of the traditional limit plate, a raised step is added at the back of the limit plate. The main purpose is to facilitate the laser rangefinder to effectively identify the jump in distance, so as to identify the edge of the outer diameter, find the edge coordinates at three different positions, and achieve the purpose of automatically detecting the center of the limit plate. Its working principle is: on the basis of the traditional limit plate, a raised step is added. Generally, 5-10 mm needs to be added to the outer diameter on one side, and the depth is ≥20 mm. The laser rangefinder emits laser and hits the initial point of the limit plate, and records the measured distance value. The laser moves horizontally. When the laser sweeps across the edge position coordinate 1, the increment of the laser ranging is greater than the value set by the program, and the laser rangefinder stops moving forward and records the coordinate value. For example: the set judgment value of the program is ≥15 mm, the initial point ranging is 300 mm, when sweeping across the edge position coordinate 1, the ranging is 320 mm, and the increment value is 20 mm, which meets the requirements of the judgment value, and the laser rangefinder stops moving forward. Similarly, the coordinates of the edge position coordinates 2 and 3 are obtained in turn. With the three coordinate values, the center coordinate of the limit plate can be calculated. The front surface of the limit plate is sprayed with a light color, such as white or milky white, to facilitate the laser to recognize the limit plate and improve the ranging accuracy.

[0096] There are two installation positions for the laser rangefinder 5:

[0097] First, as Figure 2 shown, the laser rangefinder 5 is installed on the top of the jack assembly.

[0098] Second, as Figure 16 , 17As shown in FIGS. 18, the mounting bracket 33 is fixed to the piston of the jack, the steering gear 34 is fixed on the mounting bracket 33, the laser rangefinder 5 is fixedly connected to the output shaft of the steering gear. The steering gear 34 can be positioned at any angle within the range of 0-180 degrees, with a positioning accuracy of above 0.3, for angle detection and center detection. After the laser rangefinder 5 finishes working, the steering gear angle is adjusted to turn the laser rangefinder to the edge of the inner hole of the jack piston. During tensioning, the steel strand 35 is stretched. When the steel strand 35 is stretched to the longest, the laser rangefinder will not interfere with the steel strand, enabling the laser rangefinder to pass through the hole of the tool anchor assembly and shoot at the limiting plate for angle detection and center measurement work.

[0099] Advantages of placing the laser rangefinder inside the piston: After detecting the angle and adjusting the angle, it is necessary to move back to the initial position point of the laser, and after detecting the center position, it is necessary to move the jack to the center position. For these two moving actions, the jack needs to move upward along the Y-axis. When the laser rangefinder is installed inside, the moving distance is smaller than that when installed outside, which can shorten the moving time and improve efficiency; it saves external space; when installed outside, it is easily collided, and the laser rangefinder also needs to add a protective device, while when placed inside, there is no need to worry about being collided.

[0100] The rotation mechanism A has the following two structures:

[0101] The first structure: As shown in Figure 3 、 4As shown in the figure, it includes a transverse movement base 6, an electric cylinder rotating pin 7, an electric cylinder assembly 8, a rotating lifting frame 9, a rotating lifting frame 10, a jack assembly 11, and a rotating lifting frame pin 12; the rotation mechanism A adopts a structure in which the rotating lifting frame 9 on the Y-axis guide rail is hinged to the rotating lifting frame pin 12 to realize the rotation of the rotating lifting frame; the transverse movement base 6 is hinged to the electric cylinder assembly 8, the moving end of the electric cylinder assembly 8 is connected to the lifting frame 9, and the movement of the electric cylinder assembly 8 pushes the rotating lifting frame 9 to rotate around the rotating lifting frame pin 12; a rod end joint bearing 104 supported by the spring force of a spring assembly 102 is arranged on the top mounting bracket 101 extending from the rotating lifting frame 9, and the swinging end of the rod end joint bearing 104 is connected to the jack assembly 11; the rotating lifting frame 9 is fixed with a pressure head assembly 103, and the lower end of the pressure head assembly 103 contacts the rear end of the jack assembly 11 to offset the gravity of the front end of the jack, maintaining the balance of the jack assembly; the jack assembly 11 is connected to the spring assembly 102 through the rod end joint bearing 104; the spring assembly 102 is fixed on the top mounting bracket, and the pre-tightening force is slightly greater than the weight of the lower jack assembly; the center of gravity of the jack assembly is close to the front end, and the pressure head assembly 103 contacts the rear end of the jack assembly 11; when tensioning, when the jack assembly 11 needs to move downward or swing, the downward force generated is greater than the pre-tightening force of the spring assembly, then the spring compresses and releases the downward degree of freedom, and it can be realized that when the jack may move downward or swing and generate a huge downward force during the tensioning process, the jack can have a downward degree of freedom of movement to prevent the entire equipment from being damaged.

[0102] The second structure: As Figure 5 , 6As shown in the figure, it includes a transverse moving base 6, a rotating lifting frame 9, an electric cylinder rotating pin 13, a first electric cylinder assembly 14, a rotating bracket 15, a camshaft 16, a cam 17, a cam connecting rod 18, a jack rotating pin 19, a cam contact plate 20, and a top mounting bracket 21. The rotating bracket 15 is hinged to the top mounting bracket 21. One end of the rotating bracket 15 is connected to the first top mounting bracket 111 through a first spring assembly 112, and the other end of the rotating bracket 15 is hinged to a jack assembly 11. The cam 17 is connected and hinged to the rotating bracket 15. The middle of the cam 17 connecting rod is connected to the first electric cylinder assembly 14. When the first electric cylinder assembly 14 pushes the cam assembly to swing, it pushes the jack assembly 11 to rotate around the jack rotating pin 114. The rotating bracket 15 is connected to the first top mounting bracket 111 through a rotating pin 113. The jack assembly 11 is connected to the rotating bracket 15 through a jack rotating pin 114 and a cam mechanism. One end of the rotating bracket 15 is connected to the jack assembly 11, and the other end is connected to the first spring assembly 112, so as to install the jack assembly on the rotating bracket 15 and apply a certain pre-tightening force. The lever force of the applied pre-tightening force should be slightly greater than the gravity of the jack through the lever, so as to balance the jack assembly. When tensioning, when the jack assembly needs to move downward or swing, the downward force generated is greater than the lever force of the pre-tightening force of the spring assembly, then the spring compresses, and the rotating bracket rotates clockwise around the rotating pin and releases the downward freedom of the jack. It can be realized that when the jack may move downward or swing and generate a huge downward force during the tensioning process, the jack can have the downward movement freedom to prevent the entire device from being damaged.

[0103] See Figure 2 , in the present invention, an X, Y, Z, A four-axis positioning system 2, a tensioning system 3, and a control system 4 are installed on the platform of the walking system 1 to form an independent construction equipment, so as to facilitate moving the robot to the construction position.

[0104] See Figure 7 , 8 , 9, the Z-axis guide rail 216 is connected to the Z-axis moving base 22, and the Z-axis servo motor and reducer 25, the Z-axis rack 26, and the Z-axis driving gear 27 constitute a Z-axis driving unit; the X-axis guide rail 23 is connected to the X-axis moving base 24, and the X-axis servo motor and reducer 28, the X-axis driving gear 29, and the X-axis rack 210 constitute an X-axis driving unit; the Y-axis guide rail 211, the steel wheel 212, the chain 213, the chain guide wheel 214, and the Y-axis servo motor and electric cylinder 215 constitute a Y-axis driving unit.

[0105] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than limiting the protection scope of the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. An intelligent tensioning control method, characterized in that: Including the steps: (1) Steps for setting up the four-axis positioning mechanism: Two X, Y, Z moving mechanisms are established side by side. A rotating mechanism A is respectively set at the output end of each X, Y, Z moving mechanism to establish an XYZA four-axis positioning control system. The jack is connected to the four-axis positioning control system, and a laser rangefinder is fixed on the jack; (2) Steps for positioning the horizontal distance between the positioning trolley and the tensioning beam hole: Move the XYZA four-axis positioning system to one side of the beam. The laser rangefinder measures the relative distances L1 and L2 between the laser rangefinder and the two ends of the tensioning beam, and ensure that │L1 - L2│≤5mm; (3) Steps for the four-axis positioning system to position the tensioning beam hole: Manually adjust the light spot of the laser rangefinder to the initial position point of the laser point of the AA hole limit plate of the tensioning beam and the second position point B for measuring the angle. Operate the touch screen of the four-axis positioning control system to read and store the current absolute position data of the X-axis, Y-axis, Z-axis, and A-axis of the four-axis positioning control system. Set the X and Y axis coordinates to (0, 0), and then input the drawing sizes of each hole to calculate the coordinates of the remaining holes; (4) Steps for determining the initial position point of the laser point of the limit plate and the second position point B for measuring the angle: The setting rules for the initial position point of the laser point and the second position point B for measuring the angle are that the horizontal and vertical movement paths shall not intersect with the holes of the limit plate. The initial position point of the laser point and the second position point B for measuring the angle are set at any one of the lower right corner, upper right corner, upper left corner, or lower left corner: (5) Steps for operating and downloading the initial coordinate position of the hole to be tensioned: Select the hole to be tensioned through the previous hole or next hole button. The XYZA four-axis positioning system automatically positions the initial coordinate position. After all the tensioning holes are positioned and recorded, download the initial coordinate parameters into the PLC controller; (6) Steps for measuring the angle of the limit plate: Control the four-axis positioning system to automatically shift the light spot of the laser rangefinder upward and downward, record the laser ranging displacements of the upper point and the lower point, and the four-axis positioning system automatically calculates the angle of the cross-section of the jack relative to the cross-section of the limit plate: (7) Steps for adjusting the angle of the jack: At this time, the light spot of the laser rangefinder has left the initial position point of the laser point and the second position point B for measuring the angle. Through calculation, automatically adjust the light spot of the laser rangefinder back to the initial position point of the laser point and the second position point B for measuring the angle; (8) Steps for measuring the center of the limit plate: Automatically scan the contour edge of the limit plate through the laser rangefinder, automatically read three coordinates of the contour edge of the limit plate, and then automatically calculate the center coordinate of the limit plate and the radius R of the limit plate through the three measured coordinates; The four-axis positioning system automatically judges whether the calculated radius of the limit plate is consistent with the preset radius of the limit plate. If not, it is sent to the center counter for calculation. After calculation, input the operation of automatically reading three coordinates of the contour edge of the limit plate again, and repeat the above steps until the radius of the limit plate is consistent with the preset radius of the limit plate; (9) According to the calculated center coordinates, add the distance between the laser and the center of the top to the y-axis coordinate value. Automatically move the jack to the position of the hole to be tensioned; (10)Jack front movement step: The four-axis positioning system automatically moves forward along the steel strand direction according to the previously measured angle. The forward movement distance is calculated based on the laser ranging distances at the initial position of the laser point and the second angle measurement position point B, and it automatically moves forward to move the jack to the position of the hole to be tensioned.

2. The intelligent tensioning control method according to claim 1, characterized in that: In step (3) described above, the touch screen of the four-axis positioning control system reads the current absolute position data of the X-axis, Y-axis, Z-axis, and A-axis of the four-axis positioning control system as the initial position for the automatic control of the XYZA axes.

3. The intelligent tensioning control method according to claim 1, wherein: In step (6) described above, the calculation method used by the four-axis positioning system to automatically calculate the angle of the jack cross-section relative to the cross-section of the limiting plate is: Angle A = ATAN (coordinate difference between two points on the Z-axis / distance measurement difference between two points on the Y-axis); Its adjustment steps include: 1) The XYZA servo system first moves the laser light spot to the initial coordinate position; 2) The XYZA servo system records the laser displacement through upward offset and then downward offset, and calculates the angle deviation between the laser jack and the limiting plate through trigonometric functions; 3) The XYZA servo system automatically corrects the angles of the jack and the limiting plate through the calculated angle deviation to keep them parallel; 4) The XYZA servo system compares the offset distance between the center of the limiting plate calculated through trigonometric functions with the preset center of the jack of the system, and automatically corrects the centers of the jack and the limiting plate to keep them concentric.

4. The intelligent tensioning control method according to claim 1, wherein: In step (8) described above, the method for setting the three coordinates of the contour edge of the limiting plate is: Starting from the initial position coordinates, scan to the edge of the limiting plate to the right, and automatically record and store the edge position coordinates 1 (X1, Y1); Starting from the initial position coordinates, scan to the edge of the limiting plate to the left, and automatically record and store the edge position coordinates 2 (X2, Y2); Starting from the initial position coordinates, scan to the edge of the limiting plate upward, and automatically record and store the edge position coordinates 3 (X3, Y3).

5. The intelligent tensioning control method according to claim 1 or 4, characterized in that: In step (8) described above, the method for setting the three coordinates of the contour edge of the limiting plate is measured by the laser displacement value jump change method, that is, a sudden step is set at the edge of the end face of the limiting plate. The PLC reads the displacement value of the laser displacement sensor in real time through the MODBUS bus communication protocol. When it is monitored that the laser displacement is at the position of the sudden step and the laser displacement value jumps and changes beyond the preset value, the PLC determines that the edge position coordinates are set successfully and records and saves them.

6. An intelligent tensioning robot for implementing the method according to claim 1, comprising an XYZA four-axis positioning control system composed of X, Y, and Z moving mechanisms and a rotating mechanism A, and a limiting plate, characterized in that: The X, Y, Z moving mechanisms and the rotating mechanism A are installed on the walking system platform and move along with the walking system; the jack assembly is connected to the four-axis positioning control system, and a laser rangefinder is fixed on the jack assembly. The laser rangefinder is used to measure the distance data between the jack assembly and the bridge and the data of the limiting plate, and inputs the data into the XYZA four-axis positioning control system. The XYZA four-axis positioning control system is used to control the jack assembly to align with the position of the hole to be tensioned and send the jack into the hole to be tensioned.

7. The intelligent tensioning robot according to claim 6, wherein: The rotation mechanism A adopts a structure in which the Y-axis guide rail is pin-jointed with the rotating lifting frame to realize the rotation of the rotating lifting frame; the rotating lifting frame is provided with a rod-end spherical bearing supported by the spring force of the spring assembly, and the swinging end of the rod-end spherical bearing is connected to the jack assembly; the rotating lifting frame fixes the pressing head assembly, and the lower end of the pressing head assembly contacts the rear end of the jack assembly, offsetting the gravity of the front end of the jack to maintain the balance of the jack assembly.

8. The intelligent tensioning robot according to claim 6, characterized in that: The rotation mechanism A includes a top mounting bracket fixed to the Y-axis assembly, a rotating bracket, a rotating pin, a cam link, and an electric cylinder assembly; the rotating bracket is hinged to the top mounting bracket, one end of the rotating bracket is connected to the top mounting bracket through a spring assembly, and the other end of the rotating bracket is hinged to the jack assembly; the cam is connected and hinged to the rotating bracket, the middle of the cam link is connected to the electric cylinder assembly, and under the push of the electric cylinder assembly, the cam assembly swings to push the jack assembly to rotate.

9. The intelligent tensioning robot according to claim 6, characterized in that: The laser rangefinder is installed outside the jack assembly or on the piston of the jack assembly.

10. The intelligent tensioning robot according to claim 6, characterized in that: The end face edge of the limit plate is provided with a stepped change. When the laser rangefinder measures the position of the step, the edge position is judged by the jump change of the laser displacement value.

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