Reinforcing cage fabrication equipment and welding head control methods, systems and welding processes

Abstract

This invention relates to the field of rebar cage fabrication technology, specifically disclosing a rebar cage fabrication device, a welding head control method, system, and welding process. The welding process of this invention enables automatic welding of rebar cages. The rebar cage fabrication device includes a base, a plurality of welding heads mounted on the base, and a linear guide rail on the base, with each welding head slidably mounted on the linear guide rail. It also includes a motor for driving the welding heads and a control unit for driving the motor, with each motor corresponding to one welding head. This invention, by sliding the welding heads on the linear guide rail, enables automatic control of the welding head movement using a motor, solving the problems of inconvenience and poor accuracy caused by manual adjustment of the welding heads in existing methods.

Description

Technical Field

[0001] This invention relates to the field of steel cage manufacturing technology, specifically to steel cage fabrication apparatus and welding head control methods, systems, and welding processes. Background Technology

[0002] A reinforcing cage consists of several circumferential reinforcing bars and several spiral bars. The circumferential reinforcing bars form a circular structure, and the spiral bars connect the circumferential reinforcing bars. Reinforcing cages mainly include single-spiral reinforcing cages and double-spiral reinforcing cages. A single-spiral reinforcing cage has only one spiral bar, while a double-spiral reinforcing cage uses two spiral bars arranged side by side.

[0003] The preparation of reinforcing cages involves welding processes. During the welding process, the spacing of the inner rings of the reinforcing cage needs to be adjusted according to production to ensure that the inner rings are set at as equal intervals as possible along the length of the reinforcing cage. Since the length of the reinforcing cage will change with production requirements, the position of the inner rings and the position of the welding head also need to be changed accordingly.

[0004] Existing rebar cage welding equipment includes a base on which multiple welding heads are mounted. The welding heads on these existing equipment cannot automatically move and adjust their positions on the base; instead, they require manual movement. This not only leads to inconvenience but also results in poor precision in adjusting the welding head positions. Summary of the Invention

[0005] The purpose of this invention is to provide a rebar cage fabrication device and a welding head control method, system and welding process to achieve automatic welding.

[0006] This invention is achieved through the following technical solution:

[0007] The welding process based on the above system includes the following steps:

[0008] Step A: Welding the main reinforcing bars:

[0009] A1. Set the angle and specifications of the inner ring main reinforcement;

[0010] A2. Write the angle specifications of the inner ring main reinforcement into the positioning data as the welding position and specification standard for the main reinforcement of the welded steel cage;

[0011] A3. Set the relevant parameters for each section of the entire steel cage;

[0012] A4. Manually fix the corresponding number of inner ring reinforcing bars of the steel cage to the inner ring support;

[0013] A5. Based on the relevant parameters of each section of the steel cage set in step A3, determine the target spacing, import the target spacing and the origin spacing into the input module, and control each welding head to move to the target position based on the welding system; after all welding heads have moved to the target position, the welding equipment begins to weld the main reinforcement and the inner ring.

[0014] A6. Switch the equipment to main reinforcement automatic operation mode;

[0015] A7. The steel bars are manually laid flat on the material placement platform, and the material discharge mechanism pushes the steel bars at the end of the material placement platform onto the lifting mechanism.

[0016] A8. Measure the length of the steel bars on the lifting mechanism by locating the main reinforcement bars;

[0017] A9, via L 当前钢筋长度 and L 端距 and L 标-端距max and L 上一节笼子补偿值 L was calculated 下一节笼子补偿值 ;

[0018] A10. The end distance L set by the current reinforcing cage 端距 L 上一节笼子补偿值 and L 主筋原点到首圈 The current positioning position of the main rib positioning motor is calculated.

[0019] Step B, Welding the reinforcing bar:

[0020] Weld the reinforcing bars to the main reinforcing bars according to the set number of turns per segment and the spacing between the reinforcing bars.

[0021] Furthermore, in step A9, L 下一节笼子补偿值 The calculation formula is as follows:

[0022] L 下一节笼子补偿值 =L 当前长度 -L 端距 -L 标-端距max +L 上一节笼子补偿值 When it is the first section, L 上一节笼子补偿值 =0.

[0023] Furthermore, step B includes the following steps:

[0024] B1. The reinforcing bars are manually welded to the main reinforcing bars of the steel cage;

[0025] B2. Set the winding parameters;

[0026] B3. Manually switch the equipment to automatic winding mode. When the current torque of the central shaft is less than the limit torque, it directly enters normal winding mode. When the current torque of the central shaft is greater than or equal to the limit torque, the central shaft first reverses the set angle. After the reversal is completed, it is judged again. When the current torque of the central shaft is less than the limit torque, it enters normal winding mode. When the current torque of the central shaft is greater than or equal to the limit torque, an alarm prompts manual handling.

[0027] B4. Once the set number of turns of the reinforcing bar has been reached, the operation will stop and a message will indicate that the manual winding of the reinforcing bar is complete.

[0028] Furthermore, in step A9, L 下一节笼子补偿值 The calculation formula is as follows:

[0029] L 下一节笼子补偿值 =L 当前长度 -L 端距 -L 标-端距max +L 上一节笼子补偿值 When it is the first section, L 上一节笼子补偿值 =0.

[0030] Furthermore, step B includes the following steps:

[0031] B1. The reinforcing bars are manually welded to the main reinforcing bars of the steel cage;

[0032] B2. Set the winding parameters;

[0033] B3. Manually switch the equipment to automatic winding mode. When the current torque of the central shaft is less than the limit torque, it directly enters normal winding mode. When the current torque of the central shaft is greater than or equal to the limit torque, the central shaft first reverses the set angle. After the reversal is completed, it is judged again. When the current torque of the central shaft is less than the limit torque, it enters normal winding mode. When the current torque of the central shaft is greater than or equal to the limit torque, an alarm prompts manual handling.

[0034] B4. Once the set number of turns of the reinforcing bar has been reached, the operation will stop and a message will indicate that the manual winding of the reinforcing bar is complete.

[0035] The welding process described above in this invention enables the automatic welding of reinforcing cages.

[0036] The steel cage fabrication device for the above welding process includes a base, a plurality of welding heads arranged on the base, a linear guide rail arranged on the base, and the welding heads slidably arranged on the linear guide rail; it also includes a motor for driving the welding heads to move and a control unit for driving the motor, wherein the motor is arranged in a one-to-one correspondence with the welding heads.

[0037] Existing rebar cage welding equipment includes a base on which multiple welding heads are mounted. The welding heads on these existing equipment cannot automatically move and adjust their positions on the base; instead, they require manual movement. This not only leads to inconvenience but also results in poor precision in adjusting the welding head positions.

[0038] The welding head described in this invention is equipped with a linear slider that cooperates with a linear guide rail. The linear slider is driven by a motor, and the movement of the welding head is achieved by the linear slider moving within the linear guide rail. The control unit is used to control the start and stop of the motor, and the motor can rotate forward and reverse, thereby enabling the welding head to move in different directions.

[0039] This invention achieves automatic control by sliding the welding head onto a linear guide rail, which allows the welding head to be moved using a control motor. This solves the problems of inconvenience and poor accuracy caused by manual adjustment of the welding head in existing systems.

[0040] Furthermore, to facilitate the movement of the welding heads, one end of the welding head is fixed to the base, while the remaining welding heads are slidably mounted on the linear guide rail.

[0041] Furthermore, the control unit includes a head return-to-origin sensor, an origin detection block, an encoder detection sensor, and a controller. Each welding head is equipped with a head return-to-origin sensor, an origin detection block, and an encoder detection sensor.

[0042] The head return-to-origin sensor and origin detection block are used to detect whether the original distance between two adjacent welding heads has reached the origin distance. The head return-to-origin sensor transmits the detected original distance to the controller. The controller determines whether to issue a command to start or stop the motor based on the received original distance.

[0043] The encoder detection sensor is used to detect the distance the welding head moves relative to the origin; and transmits the detected distance to the controller, which determines whether to issue a command to stop the motor based on the received distance.

[0044] The head return-to-origin sensor, origin detection block, encoder detection sensor, and controller described in this invention are all existing technologies. The head return-to-origin sensor detects the distance between two adjacent welding heads by sensing the origin detection block on the adjacent welding heads. When the distance between the two welding heads is equal to the origin distance between the two adjacent welding heads (the distance between two adjacent welding heads when each welding head returns to the origin position), the motor stops, causing each welding head to return to the origin position.

[0045] The encoder detection sensor can count the number of times the motor rotates. The displacement of one rotation of the motor is known, and the sensor count can determine the moving distance of the welding mechanism.

[0046] The following example illustrates the use of six welding heads mounted on a base, numbered 1, 2, 3, 4, 5, and 6 in sequence, with the position of head 1 fixed.

[0047] The current position of the machine head relative to the origin (i.e., the target displacement) is calculated by counting the sensors (the five machine heads are X-sensor 2, X-sensor 3, X-sensor 4, X-sensor 5, and X-sensor 6). The distance corresponding to each sensor count is calculated by the structure and denoted as L_sensor. The current position of machine head 2 is: L_current2 = X_sensor 2 * L_sensor; the current position of machine head 3 is: L_current3 = X_sensor 3 * L_sensor; the current position of machine head 4 is: L_current4 = X_sensor 4 * L_sensor; the current position of machine head 5 is: L_current5 = X_sensor 5 * L_sensor; and the current position of machine head 6 is: L_current6 = X_sensor 6 * L_sensor.

[0048] The welding head control method based on the rebar cage fabrication device includes the following steps:

[0049] S1, the head return-to-origin sensor and origin detection block transmit the detected original distance between two adjacent welding heads to the controller;

[0050] S2. The controller determines whether each welding head has returned to the origin based on the received original spacing. If any welding head has not returned to the origin, the controller sends a command to start the motor to drive each welding head to move until all welding heads have returned to the origin. When the controller determines that all welding heads have returned to the origin based on the received original spacing, it directly proceeds to step S3.

[0051] S3. When all welding heads are at the origin position, the controller controls the motor to drive each welding head to move on the linear guide rail until the encoder detection sensor detects that the moving distance of each welding head is equal to the target displacement, and the controller controls the motor to stop.

[0052] The control method described in this invention first returns all welding heads to their origin, and then determines the target displacement by using the target distance and the origin distance. Compared with directly moving each welding head to the target position, this method has a clear logic, is easy to implement, and is convenient to operate.

[0053] Further, in step S2, the controller obtains the origin distance between two adjacent welding heads when each welding head is at the origin. Within the controller, by comparing the received original distance with the stored origin distance between two adjacent welding heads, it determines whether each welding head has returned to the origin.

[0054] Furthermore, in step S2, the specific control process for each welding head to move back to its origin is as follows:

[0055] Fix the position of the welding head at one end, and use the welding head at that end as the reference point, and mark it as the first welding head. Sequentially control the second welding head to the Nth welding head adjacent to it to move back to the origin, or simultaneously control the second welding head to the Nth welding head to move back to the origin.

[0056] Further, in step S3, the controller obtains the target displacement required for each welding head to move to the target distance. The target displacement is calculated using the target distance between two adjacent welding heads and the distance from the origin.

[0057] Furthermore, in step S3, the control process for the movement of each welding head is as follows:

[0058] The position of one end of the welding head is fixed, and this end of the welding head is used as the reference point and is marked as the first head. All welding heads are sequentially named from the first head to the Nth head. The controller sequentially controls the Nth head to the second head to move to their respective target positions.

[0059] A system for controlling a steel cage fabrication device includes:

[0060] The electric motor is used to drive the welding head to move.

[0061] The input module is used to input the origin distance and the target distance;

[0062] The calculation module, electrically connected to the input module, calculates the target displacement of each welding head based on the received origin spacing and target spacing.

[0063] The control unit includes a head return-to-origin sensor, an origin detection block, an encoder detection sensor, and a controller; each welding head is equipped with a head return-to-origin sensor, an origin detection block, an encoder detection sensor, and a motor.

[0064] The controller is electrically connected to the input module and the calculation module, and is used to obtain the origin distance and the target displacement.

[0065] The head return-to-origin sensor and origin detection block are used to detect the original distance between two adjacent welding heads and transmit the detected original distance to the controller. The controller compares the received original distance with the origin distance to determine whether each welding head has returned to the origin. If a welding head has not returned to the origin, the controller controls the motor to drive the welding head to move until each welding head returns to the origin.

[0066] The encoder detection sensor is used to detect the distance the welding head moves relative to the origin; and transmits the detected distance to the controller. The controller compares the received distance with the target displacement to determine whether to issue a command to stop the motor. When the received distance equals the target displacement, the corresponding motor is stopped.

[0067] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0068] 1. This invention achieves automatic control by sliding the welding head onto a linear guide rail, which allows the welding head to move automatically using a motor. This solves the problems of inconvenient operation and poor precision caused by manual adjustment of the welding head in existing systems.

[0069] 2. The control method described in this invention can accurately control each welding joint. The system can achieve automatic control. It only requires inputting the origin distance and the target distance to automatically calculate the target displacement. The system automatically controls the welding head to move to the target position according to the target displacement. The operation is simple, convenient and accurate.

[0070] 3. The control method described in this invention allows for independent movement control of each welding head, giving the equipment greater adjustment flexibility.

[0071] 4. The welding process described in this invention employs an automatic control method, which facilitates rapid adjustment of the welding device and improves the efficiency of steel cage fabrication. Attached Figure Description

[0072] The accompanying drawings, which are included to provide a further understanding of embodiments of the invention and form part of this application, do not constitute a limitation thereof. In the drawings:

[0073] Figure 1 This is a schematic diagram of the steel cage manufacturing device of the present invention;

[0074] Figure 2 This is a flowchart of the welding head movement control method in Example 1;

[0075] Figure 3 This is a schematic diagram showing the position and spacing between the welding heads in Example 1;

[0076] Figure 4 This is a schematic diagram of the control system of the present invention;

[0077] Figure 5 A schematic diagram showing the length measurement of the reinforcing bars on the lifting mechanism for positioning the main reinforcing bars;

[0078] Figure 6 Flowchart for welding main reinforcing bars

[0079] Figure 7 This is a flowchart of the welding process for the reinforcing bar.

[0080] The attached diagram shows the markings and corresponding component names:

[0081] 1-Base, 2-Welding head, 3-Linear guide rail. Detailed Implementation

[0082] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the embodiments and accompanying drawings. The illustrative embodiments and descriptions of the present invention are only used to explain the present invention and are not intended to limit the present invention.

[0083] Example 1:

[0084] like Figures 1-4 As shown, the rebar cage fabrication device includes a base 1, on which a plurality of welding heads 2 are mounted. The base 1 is characterized by a linear guide rail 3, on which the welding heads 2 are slidably mounted. Specifically, each welding head 2 has a linear slider that cooperates with the linear guide rail 3. The linear slider moves within the linear guide rail 3 under the drive of a motor, which can rotate forward and reverse. The device also includes a motor for driving the welding heads 2 and a control unit for driving the motor, with each motor corresponding to one welding head 2.

[0085] In this embodiment, the control unit includes a head return-to-origin sensor, an origin detection block, an encoder detection sensor, and a controller. Each welding head 2 is equipped with a head return-to-origin sensor, an origin detection block, and an encoder detection sensor.

[0086] The head return-to-origin sensor and origin detection block are used to detect whether the original distance between two adjacent welding heads 2 has reached the origin distance. The head return-to-origin sensor transmits the detected original distance to the controller. The controller determines whether to issue a command to start or stop the motor based on the received original distance.

[0087] The encoder detection sensor is used to detect the distance the welding head 2 moves relative to the origin; and transmits the detected distance to the controller, which determines whether to issue a command to stop the motor based on the received distance.

[0088] In this embodiment, in order to facilitate the control of each welding head 2, one end of the welding head 2 is fixed on the base 1, and the other welding heads 2 are slidably mounted on the linear guide rail 3.

[0089] For ease of explanation, in this embodiment, the welding head 2 is provided with 6 heads, namely head 1, head 2, head 3, head 4, head 5 and head 6, wherein the position of head 1 is fixed. Specifically, the head-to-origin sensor on machine head 2 works in conjunction with the origin detection block on machine head 1 to detect the original distance between machine heads 2 and 1; the head-to-origin sensor on machine head 3 works in conjunction with the origin detection block on machine head 2 to detect the original distance between machine heads 3 and 2; the head-to-origin sensor on machine head 4 works in conjunction with the origin detection block on machine head 3 to detect the original distance between machine heads 4 and 3; the head-to-origin sensor on machine head 5 works in conjunction with the origin detection block on machine head 4 to detect the original distance between machine heads 5 and 4; and the head-to-origin sensor on machine head 6 works in conjunction with the origin detection block on machine head 5 to detect the original distance between machine heads 6 and 5.

[0090] According to the requirements for the fabrication of the reinforcing cage, the target spacing between two adjacent welding heads 2 is obtained and recorded as: L_mesh_1-2, L_mesh_2-3, L_mesh_3-4, L_mesh_4-5, L_mesh_5-6. The set spacing must meet the maximum and minimum values ​​of the head spacing, otherwise it will be invalid. The maximum and minimum values ​​have been set in advance according to the mechanical mechanism.

[0091] Obtain the origin of each welding head 2, that is, obtain the origin distance between two adjacent welding heads 2, and record it as: L_origin1-2, L_origin2-3, L_origin3-4, L_origin4-5, L_origin5-6; the origin distance can be obtained by manual measurement.

[0092] The target displacement of each welding head 2 relative to the origin is calculated based on the origin distance and target distance between two adjacent welding heads 2, and denoted as Ltarget2, Ltarget3, Ltarget4, Ltarget5, and Ltarget6. The calculation formulas for Ltarget2, Ltarget3, Ltarget4, Ltarget5, and Ltarget6 are as follows:

[0093] L target 2 = L target interval 1-2 - L original 1-2, L target 3 = L target interval 2-3 - L original 2-3 + L target 2, L target 4 = L target interval 3-4 - L original 3-4 + L target 3, L target 5 = L target interval 4-5 - L original 4-5 + L target 4, L target 6 = L target interval 5-6 - L original 5-6 + L target 5.

[0094] The welding head control method of the rebar cage fabrication device described in this embodiment includes the following steps:

[0095] S1, the head return-to-origin sensor and origin detection block transmit the detected original distance between two adjacent welding heads 2 to the controller;

[0096] S2. The controller obtains the origin distance between two adjacent welding heads 2 when each welding head 2 is at the origin. The controller determines whether each welding head 2 has returned to the origin based on the received original distance. That is, the controller compares the received original distance with the stored origin distance between two adjacent welding heads 2 to determine whether each welding head 2 has returned to the origin. When the original distance is equal to the origin distance, it is determined that it has returned to the origin. When the original distance is greater than or equal to the origin distance, it is determined that it has not returned to the origin. If any welding head 2 has not returned to the origin, the controller issues a command to start the motor to drive each welding head 2 to move until all welding heads 2 have returned to the origin. When the controller determines that all welding heads 2 have returned to the origin based on the received original distance, it directly proceeds to step S3.

[0097] The specific control process for each welding head 2 to move back to its origin is as follows:

[0098] The machine heads 2 through 6 are sequentially controlled to move back to the origin, or the machine heads 2 through 6 are simultaneously controlled to move back to the origin. The control method is to drive the motors on each welding machine head 2 through the controller, and the motors drive the linear sliders to move within the linear slide rail 3.

[0099] S3. When all welding heads 2 are at the origin position, the controller controls the motor to drive the 5 welding heads 2 to move on the linear guide rail 3 until the encoder detection sensor detects that the moving distance of each welding head 2 is equal to the target displacement, and the controller controls the motor to stop.

[0100] The control process for the movement of the 5 welding heads 2 is as follows:

[0101] First, control the No. 6 machine head to move to the target position, and then control the No. 5, No. 4, No. 3, and No. 2 machine heads to move to the target positions in sequence.

[0102] Example 2:

[0103] A system for controlling the steel cage fabrication apparatus as described in Example 1, characterized in that it comprises:

[0104] The motor is used to drive the welding head 2 to move;

[0105] The input module is used to input the origin distance and the target distance;

[0106] The calculation module, electrically connected to the input module, calculates the target displacement of each welding head 2 based on the received origin spacing and target spacing;

[0107] The calculation module stores the calculation formulas for L target 2, L target 3, L target 4, L target 5, and L target 6. The calculation formulas for L target 2, L target 3, L target 4, L target 5, and L target 6 are as follows:

[0108] L target 2 = L target interval 1-2 - L original 1-2, L target 3 = L target interval 2-3 - L original 2-3 + L target 2, L target 4 = L target interval 3-4 - L original 3-4 + L target 3, L target 5 = L target interval 4-5 - L original 4-5 + L target 4, L target 6 = L target interval 5-6 - L original 5-6 + L target 5.

[0109] Wherein, L target refers to the distance the machine head moves. For example, L target 2 refers to the distance between the machine head 2 after it moves and the original position of the machine head 2. L original refers to the distance between two adjacent machine heads in their original positions. For example, L original 1-2 represents the distance between the original positions of machine head 1 and machine head 2. L between the machine heads refers to the distance between two adjacent machine heads after they move. For example, L between the machine heads 4-5 specifically refers to the distance between machine heads 4 and 5 after they move.

[0110] The control unit includes a head return-to-origin sensor, an origin detection block, an encoder detection sensor, and a controller; each welding head 2 is equipped with a head return-to-origin sensor, an origin detection block, an encoder detection sensor, and a motor.

[0111] The controller is electrically connected to the input module and the calculation module, and is used to obtain the origin distance and the target displacement.

[0112] The head return-to-origin sensor and origin detection block are used to detect the original distance between two adjacent welding heads 2 and transmit the detected original distance to the controller. The controller compares the received original distance with the origin distance to determine whether each welding head 2 has returned to the origin. If a welding head 2 has not returned to the origin, the controller controls the motor to drive the welding head 2 to move until each welding head 2 returns to the origin.

[0113] The encoder detection sensor is used to detect the movement distance of the welding head 2 relative to the origin; and transmits the detected movement distance to the controller. The controller compares the received movement distance with the target displacement to determine whether to issue a command to stop the motor. When the received movement distance is equal to the target displacement, the corresponding motor is stopped.

[0114] Example 3:

[0115] The welding process based on the system described in Example 2 includes the following steps:

[0116] Step A: Welding the main reinforcing bars:

[0117] A1. Set the angle and specifications of the inner ring main reinforcement;

[0118] Manually input the angle ∠ of the main reinforcement bar at each location (as the position for welding on the inner ring) and the specification of the main reinforcement bar (to distinguish the length of the welded reinforcement bar). There are two methods for inputting the main reinforcement bar angle and specification: ① Manually input for each location; ② Manually input the number of main reinforcement bars multiplied by the number of main reinforcement bars, and open the specification (a total of 4 types: A, B, C, and D), and automatically calculate using a formula:

[0119] The formula for calculating the angle is: (∠main reinforcement = (X main reinforcement position - 1) * (360 ÷ X number of main reinforcements));

[0120] The formula for calculating specifications is: take the remainder of (X main reinforcement position ÷ X total number of open specifications) and then X remainder. If X remainder = 0, then X total number of open specifications is transferred to X main reinforcement specification; if X remainder <> 0, then X remainder is transferred to X main reinforcement specification.

[0121] If X main reinforcement specification = 1, it is specification A; if X main reinforcement specification = 2, it is specification B; if X main reinforcement specification = 3, it is specification C; if X main reinforcement specification = 4, it is specification D.

[0122] A2. Write the angle specifications of the inner ring main reinforcement into the positioning data as the welding position and specification standard for the main reinforcement of the welded steel cage;

[0123] After setting, manually click "Write" to write the rotation parameters in the table into the positioning data, which will serve as the welding position and specification standard for the main reinforcement of the welded steel cage. The total X specification A, total X specification B, total X specification C, total X specification D, position angle of X specification A, position angle of X specification B, position angle of X specification C, and position angle of X specification D are calculated through writing.

[0124] A3. Set the relevant parameters for each section of the entire steel cage;

[0125] Set the relevant parameters for each section of the entire steel cage (the entire cage consists of N sections, with a minimum of 1 section and a maximum of 6 sections), including X total number of sections, switch for each specification, L steel bar length, L end distance, welding head switch, and baffle position selection. The selection of "welding head switch" and "baffle position" can be written in through automatic calculation results or selected manually.

[0126] A4. Based on the relevant parameters of each section of the steel cage set in step A3, determine the target spacing, import the target spacing and the origin spacing into the input module, and control each welding head 2 to move to the target position based on the control method of the system described in Example 2 and Example 1. After all welding heads 2 have moved to the target position, move the inner circle to the position corresponding to the welding head 2.

[0127] A5. Manually fix the corresponding number of inner ring reinforcing bars of the steel cage to the inner ring support and place the corresponding main bars of the steel cage on the placing platform.

[0128] A6. Manually switch the equipment to the main reinforcement automatic operation mode;

[0129] A7. The steel bars are manually laid flat on the material placement platform, and the material discharge mechanism pushes the steel bars at the end of the material placement platform onto the lifting mechanism.

[0130] A8. Main reinforcement positioning: Measure the length of the reinforcing bars on the lifting mechanism. The calculation formula is: L 当前长度 =L 挡板距离主筋原点距离 -L 主筋定位当前位置 ,like Figure 5 As mentioned above, L 当前长度 With the L set in this section of the cage 钢筋长度 If the difference is within the set length range and the corresponding specification of steel bar has not been welded, then the steel bar needs to be welded; otherwise, the manual prompt will indicate that the steel bar needs to be discarded.

[0131] A9, via L 当前钢筋长度 and L 端距 and L 标-端距max and L 上一节笼子补偿值 L was calculated 下一节笼子补偿值 The calculation formula is: L 下一节笼子补偿值 =L 当前长度 -L 端距 -L 标-端距max +L 上一节笼子补偿值 When it is the first section, L 上一节笼子补偿值 =0;

[0132] L 标-端距max This indicates that the standard length of the rebar cage has been opened, minus the maximum actual end distance, calculated by the program based on the input parameters.

[0133] A10, End distance L set through this section of the reinforcing cage 端距 and L 上一节笼子补偿值 and L 主筋原点到首圈 The positioning position of the main rib positioning motor is calculated using the following formula: L 主筋定位 =L 主筋原点到首圈 -(L 端距 -L 上一节笼子补偿值 When it is the first section, L 上一节笼子补偿值 =0;

[0134] A11. After the welding head 2 has taken the positioned steel bar, it moves to the position of the inner ring reinforcing bar. The welding gun on the welding head 2 welds the inner ring reinforcing bar and the main bar together. After the welding is completed, check whether the welding is OK. If OK, then X welding total = X welding total + 1, X specification welding number = X specification welding number + 1. If NG, then prompt for manual processing.

[0135] A12. To determine whether the welding of the next section of the steel cage is complete, if the total number of welded sections X is greater than or equal to the total number of steel bars X, then the manual operator is prompted that the welding of this section of the cage is complete.

[0136] The flowchart for welding the main reinforcing bars is as follows: Figure 6 As shown.

[0137] Step B, Welding the reinforcing bars: Based on the set number of turns per segment and the spacing between the reinforcing bars, weld the reinforcing bars onto the main reinforcing bars:

[0138] B1. The reinforcing bars are manually welded to the main reinforcing bars of the steel cage;

[0139] B2. Set the number of turns per segment of the winding and the winding spacing (up to 10 segments can be set), single / double winding, and automatically match the central shaft speed, travel motor speed, and winding motor speed according to the set speed when winding the winding.

[0140] B3. Manually switch the equipment to automatic winding mode. When the current torque of the central shaft is less than the limit torque, it directly enters normal winding mode. When the current torque of the central shaft is greater than or equal to the limit torque, the central shaft first reverses the set angle. After the reversal is completed, it is judged again. When the current torque of the central shaft is less than the limit torque, it enters normal winding mode. When the current torque of the central shaft is greater than or equal to the limit torque, an alarm prompts manual handling.

[0141] B4. Once the set number of turns of the reinforcing bar has been reached, the operation will stop and a message will indicate that the manual winding of the reinforcing bar is complete.

[0142] B5. The welded steel cage is manually transported to the unloading position via a central shaft trolley.

[0143] The process flow chart for welding wire coils is as follows: Figure 7 As shown.

[0144] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A welding process for reinforcing steel cages, characterized in that, Includes the following steps: Step A: Welding the main reinforcing bars: A1. Set the angle and specifications of the inner ring main reinforcement; A2. Write the angle specifications of the inner ring main reinforcement into the positioning data as the welding position and specification standard for the main reinforcement of the welded steel cage; A3. Set the relevant parameters for each section of the entire steel cage; A4. Manually fix the corresponding number of inner ring reinforcing bars of the steel cage to the inner ring support; A5. Based on the relevant parameters of each section of the steel cage set in step A3, determine the target spacing, import the target spacing and the origin spacing into the input module, and the welding equipment starts welding the main reinforcement and the inner ring. A6. Switch the equipment to main reinforcement automatic operation mode; A7. The steel bars are manually laid flat on the material placement platform, and the material discharge mechanism pushes the steel bars at the end of the material placement platform onto the lifting mechanism. A8. Measure the length of the steel bars on the lifting mechanism by locating the main reinforcement bars; A9, by L 当前钢筋长度 and L 端距 and L 标-端距max and L 上一节笼子补偿值 , calculated L 下一节笼子补偿值 ; L 标-端距max : indicates the standard length of the open section of the reinforcement cage minus the maximum value of the real end distance, calculated by the program with the input parameters; A10, the end distance L set by the current reinforcement cage 端距 , L 上一节笼子补偿值 and L 主筋原点到首圈 , the positioning position of the current main reinforcement positioning motor is calculated Step B, Welding the reinforcing bar: Weld the reinforcing bars to the main reinforcing bars according to the set number of turns per segment and the spacing between the reinforcing bars.

2. The welding process according to claim 1, characterized in that, In step A9, L 下一节笼子补偿值 The calculation formula is as follows: L 下一节笼子补偿值 =L 当前长度 -L 端距 -L 标-端距max +L 上一节笼子补偿值 When it is the first section, L 上一节笼子补偿值 =0.

3. The welding process according to claim 1, characterized in that, Step B includes the following steps: B1. The reinforcing bars are manually welded to the main reinforcing bars of the steel cage; B2. Set the winding parameters; B3. Manually switch the equipment to automatic winding mode. When the current torque of the central shaft is less than the limit torque, it directly enters normal winding mode. When the current torque of the central shaft is greater than or equal to the limit torque, the central shaft first reverses the set angle. After the reversal is completed, it is judged again. When the current torque of the central shaft is less than the limit torque, it enters normal winding mode. When the current torque of the central shaft is greater than or equal to the limit torque, an alarm prompts manual handling. B4. Once the set number of turns of the reinforcing bar has been reached, the operation will stop and a message will indicate that the manual winding of the reinforcing bar is complete.

4. A steel cage fabrication apparatus for the welding process described in any one of claims 1-3, comprising a base (1) and a plurality of welding heads (2) disposed on the base (1), characterized in that, The base (1) is provided with a linear guide rail (3), and the welding head (2) is slidably mounted on the linear guide rail (3); it also includes a motor for driving the welding head (2) to move and a control unit for driving the motor, and the motor is provided in a one-to-one correspondence with the welding head (2).

5. The steel cage fabrication device according to claim 4, characterized in that, One of the welding heads (2) is fixed on the base (1), while the other welding heads (2) are slidably mounted on the linear guide rail (3).

6. The steel cage fabrication device according to claim 4, characterized in that, The control unit includes a head return-to-origin sensor, an origin detection block, a code disk detection sensor, and a controller. Each welding head (2) is equipped with a head return-to-origin sensor, an origin detection block, and a code disk detection sensor. The head return-to-origin sensor and the origin detection block are used to detect whether the original distance between two adjacent welding heads (2) reaches the origin distance. The head return-to-origin sensor transmits the detected original distance to the controller. The controller determines whether to issue an instruction to start or stop the motor based on the received original distance. The encoder detection sensor is used to detect the moving distance of the welding head (2) relative to the origin; and transmits the detected moving distance to the controller, which determines whether to issue a command to stop the motor based on the received moving distance.

7. The welding head control method based on the rebar cage fabrication device according to claim 6, characterized in that, Includes the following steps: S1, the head return-to-origin sensor and the origin detection block transmit the original distance between two adjacent welding heads (2) to the controller; S2. The controller determines whether each welding head (2) has returned to the origin based on the received original spacing. If any welding head (2) has not returned to the origin, the controller issues a command to start the motor to drive each welding head (2) to move until all welding heads (2) have returned to the origin. When the controller determines that all welding heads (2) have returned to the origin based on the received original spacing, it directly proceeds to step S3. S3. When all welding heads (2) are at the origin position, the controller controls the motor to drive each welding head (2) to move on the linear guide rail (3) until the code disk detection sensor detects that the moving distance of each welding head (2) is equal to the target displacement, and the controller controls the motor to stop.

8. The welding head control method according to claim 7, characterized in that, In step S2, the controller obtains the origin distance between two adjacent welding heads (2) when each welding head (2) is at the origin. The controller compares the received original distance with the stored origin distance between two adjacent welding heads (2) to determine whether each welding head (2) has returned to the origin.

9. The welding head control method according to claim 7, characterized in that, In step S3, the controller obtains the target displacement required for each welding head (2) to move to the target distance. The target displacement is calculated by the target distance between two adjacent welding heads (2) and the distance between the origin.

10. A system for controlling the steel cage fabrication apparatus as described in any one of claims 4-6, characterized in that, include: The motor is used to drive the welding head (2) to move; The input module is used to input the origin distance and the target distance; The calculation module is electrically connected to the input module and calculates the target displacement of each welding head (2) based on the received origin spacing and target spacing; The control unit includes a head return-to-origin sensor, an origin detection block, an encoder detection sensor, and a controller; each welding head (2) is equipped with a head return-to-origin sensor, an origin detection block, an encoder detection sensor, and a motor. The controller is electrically connected to the input module and the calculation module, and is used to obtain the origin distance and the target displacement. The head return-to-origin sensor and origin detection block are used to detect the original distance between two adjacent welding heads (2) and transmit the detected original distance to the controller. The controller compares the received original distance with the origin distance to determine whether each welding head (2) has returned to the origin. If a welding head (2) has not returned to the origin, the controller controls the motor to drive the welding head (2) to move until each welding head (2) returns to the origin. The encoder detection sensor is used to detect the moving distance of the welding head (2) relative to the origin; and transmits the detected moving distance to the controller. The controller compares the received moving distance with the target displacement and determines whether to issue a command to stop the motor. When the received moving distance is equal to the target displacement, the corresponding motor is stopped.

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