Automatic processing system for anchor rod positioning rib and working method thereof

Abstract

This invention discloses an automatic processing system for anchor bolt positioning ribs and its working method. The system includes a monitoring device and a conveying station, a welding station, and a forming station arranged sequentially. The conveying station is used to synchronously convey the anchor bolt and positioning ribs forward, and includes several sets of active conveying wheels distributed longitudinally. The welding station is used for welding and auxiliary forming, and includes several welding mechanisms pointing to the welding positions on both sides of the root of each positioning rib, and several follow-up stabilizing wheels pressing on each positioning rib. The forming station is used to form each positioning rib, and includes several forming blocks and their respective drive mechanisms. The monitoring device is used to monitor the conveying length of the anchor bolt and control the start, stop, and speed of the conveying wheels, the start and stop of the welding mechanisms, and the start, stop, and reset of the drive mechanisms. This system can automatically form and weld positioning ribs, with high work efficiency, high processing quality, and reduced labor costs.

Description

Technical Field

[0001] This invention relates to anchor bolt processing, and more specifically to an automatic processing system for anchor bolt positioning bars and its working method. Background Technology

[0002] Soil nailing walls are generally used for foundation pit support, and anchor rods are key load-bearing components. Ensuring the uniformity of the protective layer thickness of the anchor rods in the holes is crucial to ensuring that the anchor rods meet the design requirements. Therefore, "Ω"-shaped positioning bars are usually installed at intervals on the anchor rods, typically three positioning bars at each location. The outer edges of the three positioning bars rest against the holes, and the anchor rod is positioned at the center of the three positioning bars. This allows the anchor rod to be positioned in the center of the holes, meeting the requirements for the protective layer thickness.

[0003] Currently, the positioning bars are manually bent and welded onto the anchor rods, which results in low work efficiency, unreliable processing quality, and high labor costs. Summary of the Invention

[0004] The purpose of this invention is to provide an automatic processing system for anchor rod positioning bars and its working method. This system can automatically form and weld positioning bars, with high working efficiency, high processing quality, and reduced labor costs.

[0005] The technical solution adopted in this invention is:

[0006] An automatic processing system for anchor bolt positioning ribs includes a monitoring device and a conveying station, a welding station, and a forming station arranged sequentially. The conveying station is used to synchronously convey the anchor bolt and positioning ribs forward, and includes several sets of active conveying wheels distributed longitudinally. In each set, several conveying wheels clamp the anchor bolt in the center, and several conveying wheels press each positioning rib onto the anchor bolt. The welding station is used for welding and auxiliary forming, and includes several welding mechanisms pointing to the welding positions on both sides of the root of each positioning rib, and several follow-up stabilizing wheels pressing on each positioning rib. The working end of the welding mechanism and the stabilizing wheel are located at the same longitudinal position and are circumferentially offset. The stabilizing wheel is used to prevent the positioning ribs outside the forming range from lifting during forming. The forming station is used to form each positioning rib, and includes several forming blocks and their respective driving mechanisms. During forming, the forming blocks are inserted between each positioning rib and the anchor bolt and pushed forward to gradually open the positioning ribs. After reaching the position, the forming blocks are withdrawn. The monitoring device is used to monitor the conveying length of the anchor bolt and control the start and stop and speed of the conveying wheels, the start and stop of the welding mechanisms, and the start, stop, and reset of the driving mechanisms.

[0007] Preferably, the front section of the forming block is a sharp, narrow, and flat insertion section, the middle section is a smoothly expanding forming section, and the rear section is a smoothly narrowing safety section, and the bottom surface of the forming block is a plane.

[0008] Preferably, the monitoring device monitors the conveying length of the anchor rod by: setting a light sensor at the welding position to monitor whether the anchor rod has entered the welding position; and setting a rotary encoder on the conveying wheel of the anchor rod or positioning bar to monitor the movement angle of the conveying wheel after the anchor rod enters the welding position, and the conveying length of the anchor rod after entering the welding position can be obtained by calculation.

[0009] Preferably, the conveying wheels of the anchor bolt are evenly distributed in the area between the positioning ribs on the anchor bolt, and the conveying wheels of the positioning ribs are located on both sides of the upper part of the positioning ribs and are symmetrical.

[0010] Preferably, the extension length of the welding mechanism is adjustable.

[0011] Preferably, the stabilizing wheel is positioned directly above the positioning rib.

[0012] Preferably, the driving mechanism is a linear motion mechanism.

[0013] The working method of the above-mentioned automatic processing system for anchor bolt positioning ribs is as follows: First, the anchor bolt and each positioning rib are installed on the conveying position and the conveying wheel is started. The anchor bolt and each positioning rib are conveyed forward into the welding position. Then, when the monitoring device detects that the conveying length of the anchor bolt exceeds a certain distance of the welding mechanism, it controls the conveying wheel to move slowly and uniformly, while simultaneously controlling the welding mechanism to weld the welding positions on both sides of the root of each positioning rib. Then, when the monitoring device detects that the continued conveying length of the anchor bolt meets the set welding length, it controls the welding mechanism to close and controls the conveying wheel to move quickly. Then, when the monitoring device detects that the continued conveying length of the anchor bolt is the forming range length, it first controls the conveying wheel to stop, and then controls the drive mechanism to insert the forming block between each positioning rib and the anchor bolt and push it forward to gradually open the positioning rib. Since the front end of the forming range is the welding section and the rear end is a follow-up stabilizing wheel, the system ensures that the positioning ribs are gradually opened. Furthermore, since the conveyor wheel stops and therefore does not apply resistance to the positioning ribs, during the forming process, the positioning ribs upstream of the stabilizing wheel will move into the forming range to ensure that the positioning ribs can arch smoothly. The stabilizing wheel moves along with the ribs to prevent the positioning ribs outside the forming range from warping. After a certain period of time, the monitoring device controls the drive mechanism to reset and drive the forming block out. Then, the monitoring device controls the conveyor wheel to move slowly and uniformly, while controlling the welding mechanism to weld the welding positions on both sides of the root of each positioning rib. Then, when the monitoring device detects that the length of the anchor rod being conveyed meets the set welding length, it controls the welding mechanism to close and controls the conveyor wheel to move quickly. Then, when the monitoring device detects that the length of the anchor rod being conveyed meets the spacing between adjacent expansion sections, the first welding, expansion forming, and secondary welding of the next expansion section are carried out in sequence until all expansion sections along the line are processed.

[0014] The beneficial effects of this invention are:

[0015] This system can automatically shape and weld positioning ribs, resulting in high work efficiency, high processing quality, and reduced labor costs. Attached Figure Description

[0016] Figure 1 This is a cross-sectional view of the transport location in an embodiment of the present invention.

[0017] Figure 2 This is a cross-sectional view of the welding position in an embodiment of the present invention.

[0018] Figure 3 This is a cross-sectional view of the forming position in an embodiment of the present invention.

[0019] Figure 4 This is a schematic diagram of the forming process in an embodiment of the present invention.

[0020] In the diagram: 1-Anchor bolt; 2-Positioning rib; 3-Conveying wheel; 4-Welding mechanism; 5-Stabilizing wheel; 6-Forming block; 7-Drive mechanism. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0022] This embodiment discloses an automatic processing system for anchor bolt positioning bars, including a monitoring device and a conveying station, a welding station, and a forming station arranged sequentially; the conveying station is used to synchronously convey the anchor bolt 1 and the positioning bar 2 forward, such as... Figure 1 As shown, it includes several groups of active conveyor wheels 3 distributed longitudinally. In each group, several conveyor wheels 3 center and clamp the anchor rod 1, and several conveyor wheels 3 respectively press each positioning rib 2 onto the anchor rod 1; the welding position is used for welding and auxiliary forming, such as... Figure 2 As shown, it includes several welding mechanisms 4 pointing to the welding positions on both sides of the root of each positioning rib 2, and several follower-type stabilizing wheels 5 pressing on each positioning rib 2. The working end of the welding mechanism 4 and the stabilizing wheel 5 are located at the same longitudinal position and are circumferentially offset. The stabilizing wheel 5 is used to prevent the positioning rib 2 outside the forming range from lifting up during forming. The forming position is used to form each positioning rib 2, such as... Figure 3 and Figure 4 As shown, it includes several forming blocks 6 and their respective driving mechanisms 7. During forming, the forming blocks 6 are inserted between each positioning rib 2 and the anchor rod 1 and pushed forward to gradually open the positioning rib 2. After reaching the position, the forming blocks 6 are withdrawn. The monitoring device is used to monitor the conveying length of the anchor rod 1 and control the start and stop and speed of the conveying wheel 3, the start and stop of the welding mechanism 4, and the start, stop and reset of the driving mechanism 7.

[0023] Regarding the transmission bits, such as Figure 1As shown: The conveyor wheels 3 of anchor bolt 1 are evenly distributed in the area between the positioning ribs 2 on anchor bolt 1, and the conveyor wheels 3 of positioning rib 2 are located on both sides of the upper part of positioning rib 2 and are symmetrical. Since the dimensions of the conveyor wheels 3 of anchor bolt 1 and positioning rib 2 are definitely different, through conversion, the linear velocity of the conveyor wheels 3 of anchor bolt 1 and positioning rib 2 is made consistent during operation. When the dimensions of anchor bolt 1 and positioning rib 2 change, the conveyor wheels 3 of both are also adaptively replaced to avoid slippage during conveying.

[0024] Regarding the welding position, such as Figure 2 As shown: The welding mechanism 4 achieves length adjustment through electric, pneumatic, hydraulic, and manual methods. Its extension length is adjusted according to the welding effect to ensure stable and reliable welding. The stabilizing wheel 5 presses directly above the positioning rib 2, rather than pressing down from both sides, as this might interfere with or be affected by the welding mechanism 4. When the dimensions of the anchor rod 1 and the positioning rib 2 change, the stabilizing wheel 5 is also replaced accordingly, and the extension length and angle of the welding mechanism 4 are also adjusted accordingly.

[0025] Regarding the forming position, such as Figure 3 and Figure 4 As shown: the front section of the forming block 6 is a sharp, narrow, and flat insertion section; the middle section is a smoothly expanding forming section; and the rear section is a smoothly narrowing safety section. The bottom surface of the forming block 6 is flat. The insertion section is used to insert into the gap, the forming section is used to expand and shape, and the safety section adopts a smoothly narrowing structure to prevent the positioning rib 2 from expanding beyond its limit. The drive mechanism 7 is a linear motion mechanism. When the dimensions of the anchor rod 1 and the positioning rib 2 change, the installation angle of the drive mechanism 7 is adjusted so that the insertion section of the forming block 6 is aligned between the positioning rib 2 and the anchor rod 1.

[0026] The monitoring device monitors the conveying length of anchor rod 1 by: setting a light sensor at the welding position to monitor whether anchor rod 1 has entered the welding position; setting a rotary encoder on the conveying wheel 3 of anchor rod 1 or positioning rib 2 to monitor the movement angle of conveying wheel 3 after anchor rod 1 enters the welding position, and the conveying length of anchor rod 1 after entering the welding position can be obtained by conversion.

[0027] The working method of the above-mentioned automatic processing system for anchor bolt positioning ribs is as follows: First, the anchor bolt 1 and each positioning rib 2 are installed on the conveying position and the conveying wheel 3 is started, and the anchor bolt 1 and each positioning rib 2 are conveyed forward into the welding position; then, when the monitoring device detects that the conveying length of the anchor bolt 1 exceeds a certain distance of the welding mechanism 4, the conveying wheel 3 is controlled to move slowly and uniformly, while the welding mechanism 4 is controlled to weld the welding positions on both sides of the root of each positioning rib 2; then, when the monitoring device detects that the continued conveying length of the anchor bolt 1 meets the set welding length, the welding mechanism 4 is controlled to close, and the conveying wheel 3 is controlled to move quickly; then, when the monitoring device detects that the continued conveying length of the anchor bolt 1 is the forming range length, the conveying wheel 3 is first controlled to stop, such as... Figure 4As shown, the drive mechanism 7 is then controlled to insert the forming block 6 between each positioning rib 2 and the anchor rod 1 and push it forward to gradually open the positioning rib 2. Since the front end of the forming range is a welded section and the rear end is a follow-up stabilizing wheel 5, and the conveying wheel 3 stops and therefore does not apply resistance to the positioning rib 2, during the forming process, the positioning rib 2 upstream of the stabilizing wheel 5 will move into the forming range to ensure that the positioning rib 2 can arch smoothly. At the same time, the stabilizing wheel 5 follows the movement to prevent the positioning rib 2 outside the forming range from tilting up. After a certain period of time (it can be maintained for a slightly longer period of time to allow it to set), the monitoring device controls the drive mechanism. 7. Reset, causing the forming block 6 to exit; then, the monitoring device controls the conveying wheel 3 to move slowly and uniformly, while controlling the welding mechanism 4 to weld the welding positions on both sides of the root of each positioning rib 2; then, when the monitoring device detects that the length of the anchor rod 1 being conveyed meets the set welding length, it controls the welding mechanism 4 to close and controls the conveying wheel 3 to move quickly; then, when the monitoring device detects that the length of the anchor rod 1 being conveyed meets the spacing between adjacent expansion sections, the first welding, expansion forming, and secondary welding of the next expansion section are carried out in sequence until all expansion sections along the line are processed.

[0028] Although the positioning rib 2 will eventually require several expansion sections to be processed, and its initial length will be slightly longer than that of the anchor rod 1, the anchor rod is generally 12 to 10 meters long, and the positioning rib 2 will not be too long. Moreover, the positioning rib 2 is relatively thin (only needing to withstand the weight of the anchor rod 1). Even if there are excess positioning ribs 2 (unexpanded positioning ribs 2) attached to the anchor rod 1 compared to conventional methods, it will not cause too much material waste. Furthermore, the excess positioning ribs 2, together with the anchor rod 1, can strengthen the bonding effect with the protective layer, which is an additional benefit. This system can automatically shape and weld the positioning ribs 2, resulting in high work efficiency, high processing quality, and reduced labor costs.

[0029] The embodiments described above are some, but not all, of the embodiments of this application. The detailed description of the embodiments of this application is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

Claims

1. An automatic processing system for anchor bolt positioning bars, characterized in that: The system includes a monitoring device and sequentially arranged conveying, welding, and forming positions. The conveying position is used to synchronously convey the anchor bolts and positioning ribs forward. It includes several sets of active conveying wheels distributed longitudinally. In each set, several conveying wheels clamp the anchor bolts in the center, and several conveying wheels press each positioning rib onto the anchor bolt. The welding position is used for welding and auxiliary forming. It includes several welding mechanisms pointing to the welding positions on both sides of the root of each positioning rib, and several follow-up stabilizing wheels pressing on each positioning rib. The working end of the welding mechanism and the stabilizing wheel are in the same longitudinal position and are circumferentially offset. The stabilizing wheel is used to prevent the positioning ribs outside the forming range from lifting during forming. The forming position is used to form each positioning rib. It includes several forming blocks and their respective driving mechanisms. During forming, the forming blocks are inserted between each positioning rib and the anchor bolt and pushed forward to gradually open the positioning ribs. After reaching the position, the forming blocks are withdrawn. The monitoring device is used to monitor the conveying length of the anchor bolts and control the start and stop and speed of the conveying wheels, the start and stop of the welding mechanisms, and the start, stop, and reset of the driving mechanisms.

2. The automatic processing system for anchor bolt positioning bars as described in claim 1, characterized in that: The front section of the forming block is a sharp, narrow, and flat insertion section; the middle section is a smoothly expanding forming section; and the rear section is a smoothly narrowing safety section. The bottom surface of the forming block is a flat surface.

3. The automatic processing system for anchor bolt positioning bars as described in claim 1, characterized in that: The monitoring device monitors the conveying length of the anchor rod by: setting up a light sensor at the welding position to monitor whether the anchor rod has entered the welding position; and setting up a rotary encoder on the conveying wheel of the anchor rod or positioning bar to monitor the movement angle of the conveying wheel after the anchor rod enters the welding position. The conveying length of the anchor rod after entering the welding position can be obtained by calculation.

4. The automatic processing system for anchor bolt positioning bars as described in claim 1, characterized in that: The conveying wheels of the anchor bolt are evenly distributed in the area between the positioning ribs on the anchor bolt, and the conveying wheels of the positioning ribs are located on both sides of the upper part of the positioning ribs and are symmetrical.

5. The automatic processing system for anchor bolt positioning bars as described in claim 1, characterized in that: The extension length of the welding mechanism is adjustable.

6. The automatic processing system for anchor bolt positioning bars as described in claim 1, characterized in that: The stabilizing wheel is positioned directly above the positioning rib.

7. The automatic processing system for anchor bolt positioning bars as described in claim 1, characterized in that: The drive mechanism is a linear motion mechanism.

8. The working method of the automatic processing system for anchor bolt positioning bars as described in any one of claims 1 to 7, characterized in that: The working method of the automatic processing system for anchor bolt positioning ribs is as follows: First, the anchor bolt and each positioning rib are installed on the conveying position and the conveying wheel is started. The anchor bolt and each positioning rib are conveyed forward into the welding position. Then, when the monitoring device detects that the conveyed length of the anchor bolt exceeds a certain distance of the welding mechanism, it controls the conveying wheel to move slowly and uniformly, while simultaneously controlling the welding mechanism to weld the welding positions on both sides of the root of each positioning rib. Then, when the monitoring device detects that the continued conveyed length of the anchor bolt meets the set welding length, it controls the welding mechanism to close and controls the conveying wheel to move quickly. Then, when the monitoring device detects that the continued conveyed length of the anchor bolt is the forming range length, it first controls the conveying wheel to stop, and then controls the drive mechanism to insert the forming block between each positioning rib and the anchor bolt and push it forward to gradually open the positioning rib. Since the front end of the forming range is the welding section and the rear end is a follow-up stabilizing wheel, and... Furthermore, since the conveyor wheel stops and therefore does not apply resistance to the positioning ribs, during the forming process, the positioning ribs upstream of the stabilizing wheel will move into the forming range to ensure that the positioning ribs can arch smoothly. The stabilizing wheel moves along with the ribs to prevent the positioning ribs outside the forming range from warping. After a certain period of time, the monitoring device controls the drive mechanism to reset and drive the forming block out. Then, the monitoring device controls the conveyor wheel to move slowly and uniformly, while controlling the welding mechanism to weld the welding positions on both sides of the root of each positioning rib. Then, when the monitoring device detects that the length of the anchor rod being conveyed meets the set welding length, it controls the welding mechanism to close and controls the conveyor wheel to move quickly. Then, when the monitoring device detects that the length of the anchor rod being conveyed meets the spacing between adjacent expansion sections, the first welding, expansion forming, and secondary welding of the next expansion section are carried out in sequence until all expansion sections along the line are processed.

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