Moulding process method of gate chamber steel bar mesh based on short line method matching

Abstract

The application provides a short-line-method-based matching lock chamber steel bar mesh forming process method, which comprises a steel bar mesh production line, the steel bar mesh production line comprises a cloth gantry, a stepped automatic feeding mechanism, a steel bar mesh forming area and a matching reference mesh storage area; a steel bar unit is processed into a steel bar mesh by using a high-mechanical and high-automatic equipment in a factory, and then is transported to a site for butt joint and assembly; under the premise that the cost of steel bar connection is not increased, the labor intensity of manual work on site is reduced, the overall construction efficiency is improved, the influence of manual work on the construction quality of a lock chamber is reduced, the steel bar construction quality is ensured, meanwhile, the time of high-altitude work of construction personnel is effectively reduced, and the safety risk of ship lock steel bar construction is reduced.

Description

Technical Field

[0001] This invention relates to the technical field of steel reinforcement construction in lock chambers, specifically to a steel reinforcement mesh forming process based on the short-line matching method. Background Technology

[0002] Currently, the most common method for constructing steel reinforcement in ship locks is to first process the steel reinforcement units at a steel processing plant, then transport the units to the construction site. A scaffolding platform is then erected as the working platform, and the main reinforcement bars are manually moved one by one for splicing and installing horizontal reinforcement bars. This method involves labor-intensive high-altitude work, posing significant safety risks, high labor intensity, and low construction efficiency.

[0003] Currently, there are cases of optimizing the design of on-site rebar construction platforms to improve construction positioning accuracy, reduce the difficulty of rebar cage binding and positioning, and simplify the operation for construction workers. However, these methods do not fundamentally solve the problems of labor-intensive high-altitude operations, high construction safety risks, and high labor intensity, and still fall short of the requirements for industrialized construction based on modern factories. In bridge construction, some methods use precast rebar meshes that are then hoisted and connected as a whole, which improves construction efficiency, reduces on-site labor intensity, and reduces construction risks. However, the use of conical sleeve connections increases additional costs.

[0004] Therefore, it is necessary to carry out industrial transformation of lock chamber reinforcement construction, and provide a lock chamber reinforcement mesh forming process and equipment based on short-line matching, which can significantly improve the mechanization and automation of the entire lock chamber reinforcement construction process, improve construction efficiency and reduce construction costs while ensuring construction quality. Summary of the Invention

[0005] The main objective of this invention is to provide a method for forming gate chamber steel mesh based on short-line matching, thereby solving the problems mentioned in the background art.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a steel mesh production line, which includes a material feeding gantry, a stepped automatic feeding mechanism, a steel mesh forming area, and a matching reference mesh storage area; The steps of the gate chamber steel mesh forming process are as follows: S1. Divide the gate chamber steel mesh into steel unit pieces and process them according to the design dimensions. Process the external threads at the joints of the transverse steel bars and pre-install threaded sleeves. S2. Fabricate the reference steel mesh on the steel mesh production line according to the design dimensions; S3. Using the benchmark steel mesh as a reference, matching steel mesh is produced on the steel mesh production line; S4. After the matching steel mesh is formed, separate the reference steel mesh and lift it away; S5. Repeat steps S3-S4 to produce subsequent steel meshes based on the previous steel mesh.

[0007] Preferably, the specific steps of step S2 are as follows: S201. The processed steel bar unit is hoisted into the storage rack of the stepped automatic feeding mechanism, and the unit is separated one by one and conveyed to the steel mesh forming area through the stepped automatic feeding mechanism. S202. The transverse steel bar is automatically moved horizontally to the left by the transverse horizontal moving mechanism on the steel mesh forming area, so that its left end is attached to the first baffle, thereby positioning the transverse displacement of the transverse steel bar. S203. The longitudinal steel bars are laid out according to the design requirements through the material laying gantry. The spacing of the longitudinal steel bars is controlled by the travel distance of the material laying gantry to adapt to the production of mesh with different spacing. S204. After each longitudinal steel bar is laid, the automatic welding robot set on the material laying gantry performs spot welding between the intersections of the steel bars, thereby connecting and fixing the longitudinal steel bars and the transverse steel bars. S205. After the reference steel mesh is made, the first baffle is lowered, and the reference steel mesh is automatically moved to the left by the horizontal moving mechanism until it is attached to the second baffle.

[0008] Preferably, the specific steps of step S3 are as follows: S301. The unit components are separated one by one and conveyed to the steel mesh forming area by the stepped automatic feeding mechanism. S302. The transverse steel bars are automatically moved horizontally to the left by the transverse horizontal moving mechanism of the steel mesh forming area, so that the left end of the transverse steel bar is aligned with the transverse steel bar of the reference steel mesh. S303. An automatic rotary tool is used to rotate the threaded sleeve, so that the transverse reinforcing bars and the reference reinforcing mesh are matched and connected. S304. The longitudinal steel bars are laid out according to the design requirements through the material laying gantry. The spacing of the longitudinal steel bars is controlled by the travel distance of the material laying gantry to adapt to the production of mesh with different spacing. S305. After each longitudinal steel bar is laid, the automatic welding robot set on the material laying gantry performs spot welding between the intersections of the steel bars, thereby connecting and fixing the longitudinal steel bars and the transverse steel bars. S306. After the matching steel mesh is formed, rotate the threaded sleeve in the opposite direction to separate the reference steel mesh from the matching steel mesh, and then use a lifting device to lift the reference steel mesh away. S307. Use the leftward translation of the matching steel mesh as a reference for subsequent steel mesh fabrication.

[0009] Preferably, a transverse rebar positioning mechanism is provided in the rebar mesh forming area to position the spacing of the transverse rebars. The spacing between the rebar positioning mechanisms is adjustable to accommodate rebar mesh forming with different spacings.

[0010] Preferably, each longitudinal steel bar is laid out and all welding points are completed before laying the next one; or a few steel bar intersections are spot welded to position the longitudinal steel bar, and then welded by other welding machines.

[0011] This invention provides a gate chamber steel reinforcement mesh forming process based on short-line matching. In the factory, highly mechanized and automated equipment is used to process steel reinforcement units into steel reinforcement mesh, which is then transported to the site for connection and assembly. Without increasing the cost of steel reinforcement connections, this method reduces on-site labor intensity, improves overall construction efficiency, and minimizes the impact of manual labor on the quality of gate chamber construction, ensuring the quality of steel reinforcement construction. Simultaneously, it effectively reduces the time spent by construction personnel working at heights, lowering the safety risks of lock steel reinforcement construction. Attached Figure Description

[0012] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is a front view of the steel mesh production line of the present invention; Figure 2 This is the present invention. Figure 1 Top view; Figure 3 This is a schematic diagram of step S201 of the present invention; Figure 4 This is a schematic diagram of step S202 of the present invention; Figure 5 This is a schematic diagram of step S203 of the present invention; Figure 6 This is a schematic diagram of the welding of the transverse and longitudinal reinforcing bars of the present invention; Figure 7 This is a schematic diagram of step S205 of the present invention; Figure 8 This is a schematic diagram of step S301 of the present invention; Figure 9 This is a schematic diagram of the connection between the transverse and longitudinal reinforcing bars of the present invention; Figure 10 This is a schematic diagram of step S303 of the present invention; Figure 11 This is a schematic diagram of step S304 of the present invention; Figure 12 This is a schematic diagram of the lifting of the reference steel mesh of the present invention. In the diagram: 1. Fabric gantry; 2. Stepped automatic feeding mechanism; 3. Rebar mesh forming area; 4. Matching reference mesh storage area; 5. Horizontal rebar; 6. Longitudinal rebar; 7. Rebar intersection; 8. Threaded sleeve; 9. First baffle; 10. Second baffle; 11. Reference rebar mesh; 12. Matching rebar mesh. Detailed Implementation

[0013] Example 1 like Figures 1-12 As shown, the gate chamber steel mesh forming process based on short-line matching includes a steel mesh production line, which includes a material feeding gantry 1, a stepped automatic feeding mechanism 2, a steel mesh forming area 3, and a matching reference mesh storage area 4. The steps of the gate chamber steel mesh forming process are as follows: S1. Divide the gate chamber steel mesh into steel unit pieces and cut them according to the design dimensions. Perform external thread processing on the joint of the transverse steel bars 5 and pre-install threaded sleeves 8. S2. Fabricate the reference steel mesh 11 on the steel mesh production line according to the design dimensions; S3. Using the reference steel mesh 11 as a reference, the matching steel mesh 12 is produced on the steel mesh production line; S4. After the matching steel mesh 12 is formed, separate the reference steel mesh 11 and lift it away; S5. Repeat steps S3-S4, using the previous steel mesh as a reference, to produce subsequent steel meshes. A steel mesh production line is used to process the gate chamber steel mesh into shape, and the meshes are transported to the site for installation, significantly reducing on-site labor intensity, improving efficiency, and lowering construction risks.

[0014] According to the size and specifications of the steel mesh, the transverse and longitudinal steel bars that make up the steel mesh are processed using mature steel bar processing equipment. The transverse steel bars to be matched need to have external threads processed on their ends and protected. The transverse steel bars 5 and longitudinal steel bars 6 are respectively hoisted to the stepped automatic feeding mechanism 2 and the material feeding gantry 1 of the equipment. The transverse steel bars 5 are evenly fed to the steel mesh forming area 3 through the stepped automatic feeding mechanism 2 and fixed according to the design spacing through the limiting device. The longitudinal steel bars 6 are automatically fed through the material feeding gantry 1 according to the design spacing, and the welding mechanism configured on the material feeding gantry 1 is used to weld the intersection points of the transverse steel bars 5 and the longitudinal steel bars 6. After the first reference steel mesh 11 is formed, the steel mesh is automatically moved to the left by the horizontal moving mechanism. This mesh is used as the matching reference mesh for the next steel mesh matching and production. After the transverse steel bars 5 are automatically fed, the steel bars are moved to the left to align each steel bar with the transverse steel bar 5 on the reference steel mesh 11. Then, the threaded sleeve 8 is connected by rotating the automatic rotating device. After all the transverse steel bars 5 are matched, the longitudinal steel bars 6 are automatically laid out by the material feeding gantry 1 and automatically welded to complete the steel mesh matching and production.

[0015] Preferably, the specific steps of step S2 are as follows: S201. The processed steel bar unit is hoisted into the storage rack of the stepped automatic feeding mechanism 2. The stepped automatic feeding mechanism 2 separates the unit one by one and conveys them to the steel mesh forming area 3. S202. The transverse steel bar 5 is automatically moved horizontally to the left by the transverse horizontal moving mechanism on the steel mesh forming area 3, so that its left end is attached to the first baffle 9, thereby positioning the transverse displacement of the transverse steel bar 5. S203. The longitudinal steel bars 6 are laid out through the fabric gantry 1 according to the design requirements. The spacing of the longitudinal steel bars 6 is controlled by the walking distance of the fabric gantry 1 to adapt to the production of mesh with different spacing. S204. When each longitudinal steel bar 6 is laid, the automatic welding robot set on the material laying gantry 1 performs spot welding between the steel bar intersections 7, thereby connecting and fixing the longitudinal steel bar 6 and the transverse steel bar 5. S205. After the reference steel mesh 11 is made, the first baffle 9 is lowered and the reference steel mesh 11 is automatically moved to the left by the horizontal moving mechanism until it is attached to the second baffle 10.

[0016] Preferably, the specific steps of step S3 are as follows: S301, The unit components are separated one by one and conveyed to the steel mesh forming area 3 by the stepped automatic feeding mechanism 2; S302. The transverse steel bar 5 is automatically moved horizontally to the left by the transverse horizontal moving mechanism of the steel mesh forming area 3, so that the left end of the transverse steel bar 5 is aligned with the transverse steel bar 5 of the reference steel mesh 11. S303. Use an automatic rotating tool to rotate the threaded sleeve 8 so that the transverse steel bar 5 and the reference steel mesh 11 are matched and connected. S304. The longitudinal steel bars 6 are laid out through the fabric gantry 1 according to the design requirements. The spacing of the longitudinal steel bars 6 is controlled by the walking distance of the fabric gantry 1 to adapt to the production of mesh with different spacing. S305. When each longitudinal steel bar 6 is laid out, the automatic welding robot set on the material laying gantry 1 performs spot welding between the steel bar intersections 7, thereby connecting and fixing the longitudinal steel bar 6 and the transverse steel bar 5. S306. After the matching steel mesh 12 is formed, the threaded sleeve 8 is rotated in the opposite direction to separate the reference steel mesh 11 from the matching steel mesh 12. Then, the reference steel mesh 11 is lifted away by a lifting device. S307. The matching steel mesh 12 is moved to the left as a reference for subsequent steel mesh fabrication.

[0017] Preferably, a transverse steel bar positioning mechanism is provided in the steel mesh forming area 3 to position the spacing of the transverse steel bars 5. The spacing between the steel bar positioning mechanisms is adjustable to accommodate steel mesh forming with different spacings.

[0018] Preferably, each longitudinal reinforcing bar 6 is laid out and all welding points are completed before laying the next one; or a few reinforcing bar intersections 7 are spot-welded to position the longitudinal reinforcing bar 6, and then welded using other welding machines. Taking into account both efficiency and equipment cost, this improves the forming efficiency of the reinforcing mesh.

[0019] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A gate chamber steel mesh forming process based on short-line matching, characterized by: This includes a steel mesh production line, which consists of a material feeding gantry, a stepped automatic feeding mechanism, a steel mesh forming area, and a matching reference mesh storage area. The steps of the gate chamber steel mesh forming process are as follows: S1. Divide the gate chamber steel mesh into steel unit pieces and process them according to the design dimensions. Process the external threads at the joints of the transverse steel bars and pre-install threaded sleeves. S2. Fabricate the reference steel mesh on the steel mesh production line according to the design dimensions; S3. Using the benchmark steel mesh as a reference, matching steel mesh is produced on the steel mesh production line; S4. After the matching steel mesh is formed, separate the reference steel mesh and lift it away; S5. Repeat steps S3~S4 to produce subsequent steel meshes based on the previous steel mesh. The specific steps of step S2 are as follows: S201. The processed steel bar unit is hoisted into the storage rack of the stepped automatic feeding mechanism, and the unit is separated one by one and conveyed to the steel mesh forming area through the stepped automatic feeding mechanism. S202. The transverse steel bar is automatically moved horizontally to the left by the transverse horizontal moving mechanism on the steel mesh forming area, so that its left end is attached to the first baffle, thereby positioning the transverse displacement of the transverse steel bar. S203. The longitudinal steel bars are laid out according to the design requirements through the material laying gantry. The spacing of the longitudinal steel bars is controlled by the travel distance of the material laying gantry to adapt to the production of mesh with different spacing. S204. After each longitudinal steel bar is laid, the automatic welding robot set on the material laying gantry performs spot welding between the steel bar intersections, thereby connecting and fixing the longitudinal steel bar and the transverse steel bar. S205. After the reference steel mesh is made, the first baffle is lowered, and the reference steel mesh is automatically moved to the left by the horizontal moving mechanism until it is attached to the second baffle. The specific steps of step S3 are as follows: S301. The unit components are separated one by one and conveyed to the steel mesh forming area by the stepped automatic feeding mechanism. S302. The transverse steel bars are automatically moved horizontally to the left by the transverse horizontal moving mechanism of the steel mesh forming area, so that the left end of the transverse steel bar is aligned with the transverse steel bar of the reference steel mesh. S303. An automatic rotary tool is used to rotate the threaded sleeve, so that the transverse reinforcing bars and the reference reinforcing mesh are matched and connected. S304. The longitudinal steel bars are laid out according to the design requirements through the material laying gantry. The spacing of the longitudinal steel bars is controlled by the travel distance of the material laying gantry to adapt to the production of mesh with different spacing. S305. After each longitudinal steel bar is laid, the automatic welding robot set on the material laying gantry performs spot welding between the intersections of the steel bars, thereby connecting and fixing the longitudinal steel bars and the transverse steel bars. S306. After the matching steel mesh is formed, rotate the threaded sleeve in the opposite direction to separate the reference steel mesh from the matching steel mesh, and then use a lifting device to lift the reference steel mesh away. S307. Use the leftward translation of the matching steel mesh as a reference for subsequent steel mesh fabrication.

2. The gate chamber steel mesh forming process based on short-line matching according to claim 1, characterized in that: The steel mesh forming area is equipped with a transverse steel bar positioning mechanism to position the spacing of the transverse steel bars. The spacing between the steel bar positioning mechanisms is adjustable to accommodate steel mesh forming with different spacings.

3. The gate chamber steel mesh forming process based on short-line matching according to claim 1, characterized in that: After laying each longitudinal steel bar and welding all the points that need to be welded, the next one is laid; or a few steel bar intersections are spot welded to position the longitudinal steel bar, and then other automatic welding robots are used for welding.

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