Automatic processing method for prestressed concrete box girder reinforcement

Abstract

The application provides a prestressed concrete box girder steel bar automatic processing method, which comprises the following steps: step S1, bending at the first bending point, the second bending point and the third bending point of the material bar; step S2, placing the longitudinal bars corresponding to the outer side of the web plate of the steel bar cage and the longitudinal bars corresponding to the outer side of the bottom plate of the steel bar cage on the jig; step S3, sequentially hoisting the stirrup to the corresponding position in the jig, and fixing and connecting the outer side of the stirrup with the longitudinal bars corresponding to the bottom plate and the web plate; and step S4, fixing the longitudinal bars corresponding to the inner side of the web plate of the steel bar cage and the inner side of the bottom plate of the steel bar cage on the inner side of the stirrup. The stirrup is formed by bending the material bar, and the stirrup is placed in the jig to manufacture the web plate and the bottom plate corresponding to the steel bar cage, so that the binding of the steel bar cage can be quickly performed, the binding efficiency and the automation degree of the steel bar cage are effectively improved, the manual participation in the process is reduced during the construction process, and the human resources are saved.

Description

Technical Field

[0001] This invention belongs to the field of automated production technology of steel cages, and specifically relates to an automated processing method for prestressed concrete box girder steel bars. Background Technology

[0002] Box girders are a common structural form in bridge engineering, with a cross-section comprising a top slab, web, bottom slab, flanges, and a cavity. With the vigorous development of my country's transportation construction, box girder prefabrication technology has made significant progress through continuous innovation. Traditionally, the reinforcement bars for box girders are manually tied on a jig. Due to the shape limitations of the box girder, it is difficult for mechanical equipment to reach inside the reinforcement cage for operation, and excessive manual intervention results in low automation and low jig tying efficiency.

[0003] Therefore, there is a need to provide an improved technical solution that addresses the shortcomings of the existing technology. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art. This invention designs an automated processing method for prestressed concrete box girder reinforcement.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] An automated processing method for reinforcing steel bars in prestressed concrete box girders includes the following steps:

[0007] Step S1: Cut the reinforcing bars and transverse bars using the cutting equipment. Make a bend at the first bending point at both ends of the reinforcing bar. The length of the first bend is matched with the sum of the inner length of the web of the reinforcing cage and the thickness of the web of the reinforcing cage.

[0008] A second bend is made at the second bend point outside the first bend point of the reinforcing bar, so that the first bend part is distributed parallel to the reinforcing bar, and the distance between the second bend points and the first bend points is adapted to the web thickness of the reinforcing cage.

[0009] The reinforcing bar is bent three times at the three bending points inside the first bending point to form a U-shaped structure corresponding to the cross-sectional shape of the reinforcing cage. The distance between the three bending points and the first bending point is matched with the outer length of the web of the reinforcing cage.

[0010] A transverse bar is welded above the reinforcing bar, and the two ends of the transverse bar are fixedly connected to the corresponding first-bend and third-bend portions to form a stirrup.

[0011] Step S2: Place the longitudinal bars on the outer side of the web of the corresponding steel cage and the longitudinal bars on the outer side of the bottom plate of the corresponding steel cage on the jig.

[0012] Step S3: hoist the stirrups to their corresponding positions in the jig in sequence, and fix the outer side of the stirrups to the corresponding longitudinal bars in the bottom plate and web plate.

[0013] Step S4: Fix the longitudinal bars on the inner side of the web and bottom plate of the steel cage to the stirrups.

[0014] Preferably, multiple telescopic supports distributed in an array extend from the outside to the inside into the preset position of the longitudinal reinforcement in the web of the steel cage to support the longitudinal reinforcement corresponding to the web of the steel cage.

[0015] After the longitudinal reinforcement corresponding to the web of the steel cage is fixed, the telescopic support retracts to the outside of the steel cage.

[0016] Preferably, the stirrups are hoisted using a hanger, and the frame is equipped with multiple positioning seats corresponding to the hangers and the positions where the stirrups are to be placed.

[0017] Preferably, the longitudinal bars corresponding to the outer or inner side of the web of the steel cage are placed by a gantry crane, which has multiple hooks arranged in an array to place the multiple longitudinal bars.

[0018] Preferably, the stirrups are bent using a bending device, the bending device comprising:

[0019] Bending platform;

[0020] A plurality of support members are provided to position the rib material.

[0021] The bending mechanism, wherein the multiple bending mechanisms correspond to the first bending point, the second bending point and the third bending point of the rib respectively.

[0022] Preferably, the bending mechanism includes:

[0023] A rotating component, which is slidably mounted longitudinally within a bending platform to extend or retract onto the upper surface of the bending platform;

[0024] The upper end of the rotating component is provided with a rotating column and a bending column. The rotating column is concentrically distributed with the rotating component, and the spacing between the rotating column and the bending column is adapted to the outer diameter of the rib.

[0025] The driven gear has a non-circular through hole in the middle. The telescopic rod passes through the non-circular through hole from bottom to top and is fixed to the lower end of the rotating part. The outer wall of the telescopic rod corresponding to the non-circular through hole is a non-circular structure.

[0026] A driving gear meshes with the driven gear, and a power source is connected to the driving gear.

[0027] Preferably, the processing method further includes step S5.

[0028] Tie the tie bars to the web and bottom plate of the steel cage. After the tie bars are tied, place the prefabricated top plate mesh of the steel cage on the web of the steel cage. Fix four longitudinal bars at the intersection of the web of the steel cage and the top plate mesh. The four longitudinal bars are respectively attached to the inside of the four intersection points.

[0029] Preferably, the longitudinal bars corresponding to the bottom plate of the web of the steel cage are arranged by an automatic arranger, and the arranged longitudinal bars are picked up by a grabber and placed inside the stirrups.

[0030] Preferably, the automatic arranger includes a belt conveyor support and a rebar straightener. The belt conveyor support has an inner wall corresponding to the inner side of the web and bottom plate of the rebar cage. Multiple sets of conveyor belts are distributed at intervals along the length direction of the belt conveyor support to convey longitudinal reinforcement along the cross-sectional direction of the belt conveyor support.

[0031] Each set of conveyor belts includes two side belts corresponding to both sides of the conveyor support and a bottom belt corresponding to the bottom of the conveyor support. The side belts and bottom belts are staggered along the length of the conveyor support, and the side belts and bottom belts extend along the inner wall of the conveyor support on the side corresponding to the inside of the conveyor support.

[0032] The inner side of the belt conveyor is provided with a set of conveyor rollers corresponding to the lower edge of one side belt and the side edge of the bottom belt. At both ends of the belt conveyor support, there are steel bar straighteners corresponding to the two sets of conveyor rollers, so as to place the straightened longitudinal bars into the inside of the belt conveyor support through the conveyor rollers.

[0033] Both the side belt and the bottom belt are equipped with a deflector plate. On the side of the side belt corresponding to the inside of the belt conveyor bracket, the side of the deflector plate corresponding to the top is a flat surface.

[0034] On one side of the bottom belt corresponding to the inside of the belt conveyor bracket, the side of the deflector plate away from the conveyor roller group is an inclined surface, and a corresponding longitudinal rib is provided on one side of the inclined surface of the deflector plate.

[0035] Preferably, the gripper includes multiple side rods corresponding to the two side belts and a bottom rod corresponding to the bottom belt. The side rods and bottom rods are respectively hinged with gripping hooks. The side rods and bottom rods are each provided with a crossbar corresponding to the gripping hooks and sliding along the length direction of the side rods and bottom rods respectively. The gripping hooks are respectively hinged to the crossbars through strip holes, so that they can extend to grip the longitudinal ribs or retract to the outer side of the gripper under the drive of the crossbars.

[0036] Beneficial effects: By bending the reinforcing bars to form stirrups, and placing the stirrups in the jig to fabricate the web and bottom plates of the reinforcing cage, the reinforcing cage can be tied quickly, effectively improving the tying efficiency and automation level of the reinforcing cage. It also reduces manual intervention in the construction process and saves human resources. Attached Figure Description

[0037] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. Wherein:

[0038] Figure 1 This is a schematic diagram of a single bend in a specific embodiment provided by the present invention;

[0039] Figure 2 This is a schematic diagram of a secondary bending process in a specific embodiment of the present invention;

[0040] Figure 3 This is a schematic diagram of three bends in a specific embodiment provided by the present invention;

[0041] Figure 4 This is a schematic diagram of the stirrups being placed into the jig in a specific embodiment of the present invention;

[0042] Figure 5 This is a schematic diagram showing the placement of the longitudinal reinforcement bars on the inner side of the web of the steel cage in a specific embodiment provided by the present invention;

[0043] Figure 6 This is a simplified structural diagram of the overhead crane provided in a specific embodiment of the present invention;

[0044] Figure 7 This is a simplified diagram of the telescopic support structure in a specific embodiment of the present invention;

[0045] Figure 8 This is a simplified assembly diagram of the bending mechanism in a specific embodiment of the present invention;

[0046] Figure 9 This is a simplified diagram of the positioning plate structure in a specific embodiment of the present invention;

[0047] Figure 10 This is a simplified structural diagram of the automatic layout device provided in a specific embodiment of the present invention;

[0048] Figure 11 for Figure 10 Enlarged view of point A in the middle;

[0049] Figure 12 This is a schematic diagram of the assembly of the grab hook in a specific embodiment of the present invention.

[0050] In the diagram: 1. Jig; 2. Overhead crane; 3. Telescopic support; 4. Bending platform; 5. Main rod; 6. Positioning plate; 7. Slide plate; 8. Longitudinal reinforcement; 9. Stirrup; 10. Lifting rod; 11. Half gear; 12. Drive gear; 13. Hook; 14. Lifting frame; 15. Extrusion rod; 16. Limiting component; 17. Positioning protrusion; 18. Assembly rod; 19. Limiting post; 20. Drive rod; 21. Slide rod; 22. Connecting rod; 23. Telescopic rod; 24. Slide rod 25. Sleeve; 26. Support piece; 27. Rotating body; 28. First bending point; 29. ​​Second bending point; 30. Third bending point; 31. Sleeve; 32. Driven gear; 33. Drive gear; 34. Sealing plate; 35. Belt conveyor support; 36. Base frame; 37. Side belt; 38. Bottom belt; 39. Altering plate; 40. Side rod; 41. Grab hook; 42. Conveyor roller; 43. Card holder; 44. Crossbar; 45. Bottom rod. Detailed Implementation

[0051] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0052] In the description of this invention, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," and "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and do not require the invention to be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on the invention. The terms "connected" and "linked" used in this invention should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; they can refer to a direct connection or an indirect connection through intermediate components. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0053] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0054] like Figure 1-12As shown, an automated processing method for prestressed concrete box girder reinforcement includes the following steps: Step S1, the reinforcement bars and transverse bars are cut using a cutting device. The reinforcement bars are bent to form stirrups 9. Multiple stirrups 9 are distributed at intervals along the length of the reinforcement cage. Multiple stirrups 9 are welded to longitudinal bars 8 to form the web and bottom plate of the reinforcement cage. First, the reinforcement bars are placed on a bending device. First, a bend is made at the first bending point at both ends of the reinforcement bars. The angle of the first bend is the same as the angle between the outer side of the web and the top plate. The length of the first bend is matched with the sum of the inner length of the web of the reinforcement cage and the thickness of the web of the reinforcement cage.

[0055] A second bend is performed on the outer side of the first bend point 28 corresponding to the reinforcing bar. The angle of the second bend is the same as the angle between the inner side of the web and the top plate. The second bend makes the part of the first bend parallel to the reinforcing bar (the part corresponding to the outer side of the bottom plate of the steel cage). The distance between the second bend point 29 and the first bend point 28 is adapted to the thickness of the web of the steel cage, thereby forming the part of the web of the steel cage corresponding to the stirrup 9.

[0056] The reinforcing bar is bent three times at the third bending point inside the first bending point 28. The angle of the third bending is the same as the angle between the outer side of the web and the bottom plate, so that the reinforcing bar is formed into a U-shaped structure corresponding to the cross-sectional shape of the reinforcing cage. The distance between the third bending point and the first bending point 28 is adapted to the outer side length of the web of the reinforcing cage, so that the two ends of the reinforcing bar contact the middle after bending, and are preferably fixed by welding. Transverse bars are welded above the reinforcing bar. The two ends of the transverse bars are fixedly connected to the corresponding first bending part and the third bending part to form stirrups 9. The spacing between the transverse bars and the part of the middle of the reinforcing bar corresponding to the outer side of the bottom plate is adapted to the thickness of the bottom plate, so as to form stable stirrups 9. The modular welding of the reinforcing cage improves welding efficiency and reduces the difficulty of binding the reinforcing cage, thus enabling automated construction.

[0057] Step S2: Place the corresponding longitudinal reinforcement bars 8 on the outer side of the web of the box girder reinforcement cage on the assembly frames on both sides of the jig 1. Position the corresponding longitudinal reinforcement bars 8 using reinforcement hooks. Place the corresponding longitudinal reinforcement bars 8 on the outer side of the bottom plate of the box girder reinforcement cage at the bottom of the jig 1. The jig 1 is a U-shaped frame, with its interior used for binding the reinforcement cage. The length of the jig 1 is adapted to the length of the box girder reinforcement cage. The bottom of the jig 1 has multiple positioning blocks corresponding to the longitudinal reinforcement bars 8 on the outer side of the bottom plate of the reinforcement cage. The positioning blocks are arranged in a square array, with an upward-opening groove in the center of each block to position the longitudinal reinforcement bars 8 on the outer side of the bottom plate.

[0058] Step S3: The stirrups 9 are hoisted to their corresponding positions in the jig 1 in sequence. The stirrups 9 are hoisted by a special hoist. The hoist includes a main rod 5 and a positioning plate 6 connected in an I-shape. The main rod 5 and the positioning plate 6 are connected by two hydraulic cylinders. Hooks corresponding to the upper ends of the stirrups 9 are provided at both ends of the main rod 5. The positioning plate 6 is located above the bottom plate stirrups 9. A positioning protrusion 17 is provided in the middle of the positioning plate 6. The two ends of the positioning protrusion 17 are inclined end faces corresponding to the web of the stirrups 9. The two ends of the positioning protrusion 17 are adjusted longitudinally by the hydraulic cylinders to make the two ends of the positioning protrusion 17 fit tightly against the inner side of the web of the stirrups 9. Slide plates 7 are provided at both ends of the positioning plate 6. The slide plates 7 are slidably assembled along the length of the positioning plate 6. The thickness of the slide plates 7 is adapted to the positioning plate 6. An inclined surface corresponding to the web stirrups 9 is provided on the inner side of the slide plates 7. A groove for the inner reinforcing bar of the web stirrups 9 is provided on the inner side of the slide plates 7 to clamp the inner reinforcing bar of the web stirrups 9.

[0059] The sliding protrusion of the positioning plate 6 extends from the middle of the slide plate 7. The positioning plate 6 has strip grooves 25 corresponding to the sliding protrusion at both ends. The back of the positioning plate 6 is provided with hydraulic cylinders corresponding to the two slide plates 7. The hydraulic cylinders extend along the length of the positioning plate 6. The piston ends of the two hydraulic cylinders are respectively connected to the sliding protrusions of the two slide plates 7, thereby driving the slide plates 7.

[0060] The length of the positioning plate 6 extending beyond the positioning protrusions 17 at both ends is no greater than the width of the web. After clamping the inner reinforcing bars of the web corresponding to the stirrups 9, the two ends of the positioning plate 6 will not extend beyond the sides of the stirrups 9, thus facilitating placement.

[0061] After placement by the hanger, the outer side of the stirrup 9 is fixedly connected to the corresponding longitudinal reinforcement 8 at the bottom plate and web plate. Specifically, it can be welded by an automatic welding arm or fixed by steel bar binding.

[0062] Step S4: Fix the longitudinal bars 8 on the inner side of the web and bottom plate of the steel cage to the inner side of the stirrups 9. After fixing the inner longitudinal bars 8, the web and bottom plate of the steel cage are formed as a whole. In this way, the assembly difficulty is reduced by modular splicing, which can greatly improve the binding efficiency and automation of the steel cage and reduce the manual intervention process during construction.

[0063] In an optional embodiment, both the inner and outer longitudinal reinforcement bars 8 of the reinforcing cage can be supported by telescopic brackets 3. Specifically, the telescopic brackets 3 can be used to support the inner and outer sides depending on their telescopic positions, or the telescopic brackets 3 can only support the inner longitudinal reinforcement bars 8 of the web of the reinforcing cage. The jig 1 is provided with corresponding steel bar hooks for the outer longitudinal reinforcement bars 8, and multiple steel bar hooks are evenly distributed on the side wall of the jig 1. Correspondingly, multiple telescopic brackets 3 are also arrayed on the side wall of the jig 1. The telescopic brackets 3 can extend from the outside to the inside of the jig 1 to the position of the longitudinal reinforcement bar 8 corresponding to the web, thereby supporting the longitudinal reinforcement bar 8 corresponding to the web of the reinforcing cage. This ensures the stability of the longitudinal reinforcement bar 8 during the fixing process. After the longitudinal reinforcement bar 8 corresponding to the web of the reinforcing cage is fixed, the telescopic brackets 3 retract to the outside of the reinforcing cage, specifically retracting to the outside of the inner side of the jig 1. This prevents movement interference with the already tied reinforcing cage, allowing the reinforcing cage to be lifted out of the jig 1. The main body of the telescopic bracket 3 is columnar, with a limiting post 19 at its front end, thereby limiting the position of the longitudinal reinforcement bar 8 by stopping it.

[0064] The side of the jig frame 1 is a grid structure composed of multiple assembly rods 18 evenly distributed along its length. The telescopic brackets 3 are assembled on one side of the jig frame 1 along the length of the assembly rods 18. The multiple telescopic brackets 3 corresponding to the same assembly rod 18 are in the same column. The multiple telescopic brackets 3 on the same assembly rod 18 are hinged to the same slide rod 21. The slide rod 21 is fixedly connected to the sliding sleeve 24 of the corresponding telescopic bracket 3. The slide rod 21 is slidably assembled along the length of the assembly rod 18. The slide rod 21 is a square steel. A dovetail-shaped protrusion extending along its length can be provided on the slide rod 21. The assembly rod 18 is provided with a dovetail groove extending along the length of the assembly rod 18 for sliding assembly of the dovetail-shaped protrusion.

[0065] At both ends of the assembly rod 18, there are drive rods 20 corresponding to the slide rods 21. The drive rods 20 can be hydraulic cylinders. At one end of the telescopic bracket 3 corresponding to the inner side of the steel cage, there is a limiting post 19 extending upward parallel to the assembly frame. This can position the inner longitudinal reinforcement 8. The telescopic bracket 3 slides down as a whole to make way for the inner longitudinal reinforcement 8, avoiding movement interference between the limiting post 19 and the longitudinal reinforcement 8 during the retraction of the telescopic bracket 3. The ends of multiple telescopic brackets 3 on the same assembly rod 18 away from the box girder steel cage are fixedly connected to the same connecting rod 22. The connecting rod 22 drives the same row of telescopic brackets 3 synchronously through the hydraulic cylinder or electric cylinder. The hydraulic cylinder is hinged to the slide rod 21. There is a hydraulic cylinder or electric cylinder at both ends of the connecting rod 22.

[0066] In this embodiment, the length of the main rod 5 is greater than the width of the upper end of the frame 1. The stirrup 9 is lifted and transported by the hanger. The frame 1 is provided with multiple positioning seats corresponding to the hangers and the positions where the stirrup 9 is to be placed.

[0067] The positioning seat is detachably fixed to both sides of the jig frame 1 by bolts. The positioning seat is provided with a notch for engaging the main rod 5, thereby limiting the position of the main rod 5 and ensuring the placement accuracy of the stirrup 9.

[0068] In one optional embodiment, multiple longitudinal bars 8 corresponding to the outer side of the web of the steel cage are placed by a gantry crane 2, on which multiple hooks 13 are arrayed to place the multiple longitudinal bars 8.

[0069] The gantry crane 2 is a square truss corresponding to the web of the box girder's reinforcing cage, welded from square steel. Hooks 13 corresponding to the reinforcing mesh are arrayed on the lower surface of the gantry crane 2. Each hook 13 includes a longitudinally extending body and a hook portion. The hook portion of the hook 13 faces one side of the width direction of the jig 1. Multiple lifting rods 10 are hinged to the upper part of the gantry crane 2 (jig 1), evenly distributed along its length. The lifting rods 10 can be hydraulic rods. The upper ends of the lifting rods 10 are fixedly connected to a traveling beam. Both ends of the traveling beam travel on guide rails extending along the width direction of the jig 1. These guide rails are positioned above the processing workshop, thus enabling the lifting and transport of the longitudinal reinforcing bars 8. The lower ends of the lifting rods 10 are hinged to the upper surface of the gantry crane 2 via hinge shafts extending along the length direction of the jig 1.

[0070] An angle adjustment device is provided between each lifting boom 10 and the gantry crane 2 to adjust the angle of multiple longitudinal bars 8 of the corresponding box girder reinforcement cage web. The angle adjustment device includes a half gear 11 and a drive gear 12 that mesh with each other. The half gear 11 is fixed to the upper surface of the gantry crane 2 by welding. The drive gear 12 is smaller than the half gear 11 and is rotatably connected to the side of the lifting boom 10. The drive gear 12 is driven by a first stepper motor. During the angle adjustment process, the first stepper motors of multiple angle adjustment devices operate synchronously. Multiple lifting booms 10 and multiple first stepper motors can be connected to the same control panel.

[0071] To further ensure the stability of the longitudinal reinforcement 8 during hoisting and rotation, a lifting frame 14 is provided below the gantry crane 2. The lifting frame 14 is a square truss that matches the shape of the gantry crane 2. The lifting frame 14 has multiple sliding holes corresponding to the main body of the hook 13. The gantry crane 2 has multiple pressing rods 15 corresponding to the lifting frame 14. The pressing rods 15 are electric cylinders or hydraulic cylinders, which can drive the lifting frame 14 to slide along the main body of the hook 13. Below the lifting frame 14, there is a limiting member 16 corresponding to the hook 13. The limiting member 16 is plate-shaped, and the middle of the limiting member 16 has an inverted V-shaped notch corresponding to the longitudinal reinforcement 8. The longitudinal reinforcement 8 is pressed into the hook of the hook 13 through the V-shaped notch.

[0072] The number of limiting members 16 can be adapted to the number of hooks 13, or they can be set only at both ends of the longitudinal ribs 8, or they can be distributed at intervals on the lifting frame 14.

[0073] In an optional embodiment, the stirrup 9 is bent by a bending device, which includes a bending platform 4 and bending mechanisms. The upper surface of the bending platform 4 is provided with multiple abutments 26. There are multiple abutments 26, one of which is located at one end of the stirrup, and the other abutments 26 are equidistantly distributed along the non-bending side of the stirrup to position it. The multiple bending mechanisms correspond to the first bending point 28, the second bending point 29, and the third bending point 30 of the stirrup, respectively. The multiple bending mechanisms are controlled independently, so that each bending point can be bent according to the actual bending process.

[0074] The bending mechanism includes a rotating component, a driven gear 32, and a driving gear 33. The rotating component is a solid metal column. The bending platform 4 has a longitudinally arranged assembly hole corresponding to the rotating component. The rotating component is slidably assembled in the assembly hole along the longitudinal direction to extend or retract onto the upper surface of the bending platform 4. A rotating column and a bending column are fixed on the upper end face of the rotating component. The rotating column and the rotating component are concentrically distributed. The distance between the rotating column and the bending column is adapted to the outer diameter of the rib. Thus, when the rotating body 27 rotates, the rib is bent by the constraint of the rotating column and the bending column.

[0075] The driven gear 32 is rotatably connected in the assembly hole. The side wall of the assembly hole is provided with a notch corresponding to the driven gear 32, or the sleeves 31 that longitudinally abut against the upper and lower ends of the driven gear 32 form an assembly hole. The end face of the driven gear 32 is provided with a disc-shaped protrusion corresponding to the sleeve 31. The middle part of the driven gear 32 is provided with a non-circular through hole (preferably hexagonal). The non-circular through hole is preferably hexagonal and concentric with the disc-shaped protrusion and the driven gear 32.

[0076] The telescopic rod 23 can be a hydraulic cylinder or an electric cylinder. Its piston end passes through a non-circular perforation from bottom to top and is fixed to the lower end of the rotating part. The upper end of the piston end is welded and fixed to the bottom of the rotating body 27. The outer wall of the part of the telescopic rod 23 corresponding to the non-circular perforation is a non-circular structure (preferably hexagonal). The driving gear 33 meshes with the driven gear 32. A power source is connected to the driving gear 33. The power source can be a stepper motor.

[0077] A sealing plate 34 is fixed at the lower end of the assembly hole (or in the middle of the sleeve 31 below). The lower end of the telescopic rod 23 is provided with flanges corresponding to the upper and lower surfaces of the sealing plate 34, thereby forming a rotating connection. The telescopic rod 23 drives the rotating part. During bending, the upper surface of the rotating part is on the same plane as the bending platform 4. During the first bend, the rotating part at the second bending point 29 retracts into the assembly hole. During the second bend, all the rotating parts at the three points rise upward. During the third bend, the rotating parts at the first and second bending points 29 retract into the assembly hole. After each stirrup 9 is bent, each rotating body 27 returns to its original position.

[0078] In an optional embodiment, the processing method further includes step S5, which involves binding tie bars at the web and bottom plate positions of the reinforcing cage. The tie bars are connected to the inner and outer sides of the web and side plates respectively. After the tie bars are bound, the prefabricated top plate mesh of the reinforcing cage is placed above the web of the reinforcing cage. Four longitudinal bars 8 are fixed at the intersection of the web and the top plate mesh. The four longitudinal bars 8 are respectively attached to the inner side of the four intersection points at the intersection, and the top plate and web are fixedly connected to form a complete reinforcing cage. At this time, the reinforcing cage can be lifted out for the next construction process.

[0079] In one optional embodiment, the longitudinal bars 8 corresponding to the inner side of the bottom plate and web of the steel cage are grabbed and hoisted at once by a grabber, and the longitudinal bars 8 corresponding to the bottom plate of the web of the steel cage are arranged by an automatic arranger. After the arranged longitudinal bars 8 are grabbed by the grabber, they are placed inside the stirrups 9.

[0080] The automatic arrangement device includes a belt conveyor support 35 and a rebar straightener. The belt conveyor support 35 is a U-shaped frame. The belt conveyor support 35 has a side wall corresponding to the web of the rebar cage and a bottom surface corresponding to the bottom plate, so that the longitudinal reinforcement 8 maintains a corresponding arrangement angle with the web and bottom plate of the rebar cage after placement. Multiple sets of conveyor belts are distributed at intervals along the length direction of the belt conveyor support 35 to convey the longitudinal reinforcement 8 along the cross-sectional direction of the belt conveyor support 35. In this application, there are at least three sets of conveyor belts.

[0081] Each set of conveyor belts includes two side belts 37 corresponding to both sides of the conveyor belt support 35 and a bottom belt 38 corresponding to the bottom of the conveyor belt support 35. The side belts 37 and bottom belts 38 are assembled by multiple positioning rollers and driven by independent stepper motors. The side belts 37 and bottom belts 38 are staggered along the length of the conveyor belt support 35 so that they do not interfere with each other. The side belts 37 and bottom belts 38 extend along the inner wall of the conveyor belt support 35 on the side corresponding to the inside of the conveyor belt support 35, so that the longitudinal reinforcement 8 can be conveyed according to the web and bottom plate of the steel cage. The inner side of the conveyor belt is provided with a set of conveyor rollers 42 corresponding to the lower edge of one of the side belts 37 and the side edge of the bottom belt 38. Each set of conveyor rollers 42 includes multiple conveyor rollers 42 spaced apart along the length of the conveyor belt support 35. The conveyor rollers 42 have an annular groove in the middle to limit the longitudinal reinforcement 8.

[0082] At both ends of the belt conveyor support 35, there are steel bar straighteners corresponding to two sets of conveyor rollers 42. The straightened longitudinal steel bar 8 moves along multiple conveyor rollers 42, so that the straightened longitudinal steel bar 8 is positioned inside the belt conveyor support 35 through the conveyor rollers 42 for conveying by the side belt 37 or the bottom belt 38.

[0083] Both the side belt 37 and the bottom belt 38 are equipped with a baffle plate 39. The spacing of the baffle plate 39 is adapted to the spacing of the corresponding longitudinal ribs 8. On the side of the side belt 37 corresponding to the inside of the belt conveyor bracket 35, the side of the baffle plate 39 corresponding to the upper side is flat. In this way, during the upward conveying process of the side belt 37, the corresponding longitudinal ribs 8 can be lifted up and then conveyed upward. The straightening of the longitudinal ribs 8 and the conveying of the side belt 37 run in sequence until the arrangement of the longitudinal ribs 8 on that side is completed.

[0084] On one side of the bottom belt 38 corresponding to the inside of the belt conveyor bracket 35, the side of the deflector 39 away from the conveyor roller 42 is inclined, so that the longitudinal rib 8 can be deflected out of the annular groove through the inclined surface. A corresponding bracket 43 for the longitudinal rib 8 is provided on one side of the inclined surface of the deflector 39. The bracket 43 is lower than the deflector 39, so that the longitudinal rib 8 can be positioned. At the intersection of the bottom belt 38 and another side belt 37, the longitudinal rib 8 conveyed on the bottom belt 38 is continued to be conveyed by the deflector 39 on the side belt. The straightener and the bottom belt 38 and side belt 37 are conveyed in sequence until the arrangement of the longitudinal rib 8 corresponding to the bottom plate and the other side web plate is completed.

[0085] In this embodiment, the gripper includes multiple side rods 40 corresponding to the two side belts 37 and bottom rods 45 corresponding to the bottom belt 38. A hanging rail extending to the frame 1 is provided above the belt conveyor support 35. The gripper is connected to the hanging rail above. The main rod 5 of the gripper is a hydraulic cylinder, with a traveling beam fixed to the upper end. Both ends of the traveling beam move along the hanging rail. A base frame 36 is provided at the bottom of the gripper, and the side rods 40 and bottom rods 45 are provided on the base frame 36. Hooks 41 are hinged to the side rods 40 and bottom rods 45 respectively. The spacing between the hooks 41 is the same as the spacing between the longitudinal ribs 8. A pair of hooks is provided on both the side rods 40 and bottom rods 45. The crossbar 44, which is attached to the hook 41 and slides along the length of the side bar 40 and the bottom bar 45 respectively, is connected to the crossbar 44 through the strip hole. The hook 41 extends to grab the longitudinal rib 8 or retracts to the outer side of the gripper under the drive of the crossbar 44. The crossbar 44 is driven by an electric cylinder. The two ends of the crossbar 44 are slidably mounted on the ear plate to restrict the path. When the crossbar 44 moves laterally, it drives the hook 41 to rotate, so that it can grab. In this embodiment, the hook part of the hook 41 on the bottom bar 45 points to one side of the belt conveyor bracket 35, and the hook part on the side bar 40 points to the upper end of the side bar 40.

[0086] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention shall be within the scope of protection of the pending claims of the present invention.

Claims

1. An automated processing method for reinforcing bars in prestressed concrete box girders, characterized in that, Includes the following steps: Step S1: Cut the reinforcing bars and transverse bars using the cutting equipment. Make a bend at the first bending point at both ends of the reinforcing bar. The length of the first bend is matched with the sum of the inner length of the web of the reinforcing cage and the thickness of the web of the reinforcing cage. A second bend is made at the second bend point outside the first bend point of the reinforcing bar, so that the first bend part is distributed parallel to the reinforcing bar, and the distance between the second bend points and the first bend points is adapted to the web thickness of the reinforcing cage. The reinforcing bar is bent three times at the three bending points inside the first bending point to form a U-shaped structure corresponding to the cross-sectional shape of the reinforcing cage. The distance between the three bending points and the first bending point is matched with the outer length of the web of the reinforcing cage. A transverse bar is welded above the reinforcing bar, and the two ends of the transverse bar are fixedly connected to the corresponding first-bend and third-bend portions to form a stirrup. Step S2: Place the longitudinal bars on the outer side of the web of the corresponding steel cage and the longitudinal bars on the outer side of the bottom plate of the corresponding steel cage on the jig. Step S3: hoist the stirrups to their corresponding positions in the jig in sequence, and fix the outer side of the stirrups to the corresponding longitudinal bars in the bottom plate and web plate. Step S4: Fix the longitudinal bars on the inner side of the web and bottom plate of the steel cage to the stirrups.

2. The automated processing method for prestressed concrete box girder reinforcement according to claim 1, characterized in that, Multiple telescopic supports distributed in an array extend from the outside to the inside into the preset positions of the longitudinal reinforcement bars in the web of the steel cage to support the corresponding longitudinal reinforcement bars in the web of the steel cage. After the longitudinal reinforcement corresponding to the web of the steel cage is fixed, the telescopic support retracts to the outside of the steel cage.

3. The automated processing method for prestressed concrete box girder reinforcement according to claim 1, characterized in that, The stirrups are hoisted using a hanger, and the frame is equipped with multiple positioning seats corresponding to the hangers and the positions where the stirrups are to be placed.

4. The automated processing method for prestressed concrete box girder reinforcement according to claim 1, characterized in that, The longitudinal bars corresponding to the outer or inner sides of the web of the steel cage are placed by a gantry crane, which has multiple hooks arranged in an array to place the multiple longitudinal bars.

5. The automated processing method for prestressed concrete box girder reinforcement according to claim 1, characterized in that, The stirrups are bent using a bending device, which includes: Bending platform; A plurality of support members are provided to position the rib material. The bending mechanism, wherein the multiple bending mechanisms correspond to the first bending point, the second bending point and the third bending point of the rib respectively.

6. The automated processing method for prestressed concrete box girder reinforcement according to claim 5, characterized in that, The bending mechanism includes: A rotating component, which is slidably mounted longitudinally within a bending platform to extend or retract onto the upper surface of the bending platform; The upper end of the rotating component is provided with a rotating column and a bending column. The rotating column is concentrically distributed with the rotating component, and the spacing between the rotating column and the bending column is adapted to the outer diameter of the rib. The driven gear has a non-circular through hole in the middle. The telescopic rod passes through the non-circular through hole from bottom to top and is fixed to the lower end of the rotating part. The outer wall of the telescopic rod corresponding to the non-circular through hole is a non-circular structure. A driving gear meshes with the driven gear, and a power source is connected to the driving gear.

7. The automated processing method for prestressed concrete box girder reinforcement according to claim 1, characterized in that, The processing method further includes step S5. Tie the tie bars to the web and bottom plate of the steel cage. After the tie bars are tied, place the prefabricated top plate mesh of the steel cage on the web of the steel cage. Fix four longitudinal bars at the intersection of the web of the steel cage and the top plate mesh. The four longitudinal bars are respectively attached to the inside of the four intersection points.

8. The automated processing method for prestressed concrete box girder reinforcement according to claim 1, characterized in that, The longitudinal bars corresponding to the bottom plate of the web of the steel cage are arranged by an automatic arranger, and the arranged longitudinal bars are picked up by a grabber and placed inside the stirrups.

9. The automated processing method for prestressed concrete box girder reinforcement according to claim 8, characterized in that, The automatic arrangement device includes a belt conveyor support and a rebar straightener. The belt conveyor support has an inner wall corresponding to the inner side of the web and bottom plate of the rebar cage. Multiple sets of conveyor belts are distributed at intervals along the length direction of the belt conveyor support to convey longitudinal reinforcement along the cross-sectional direction of the belt conveyor support. Each set of conveyor belts includes two side belts corresponding to both sides of the conveyor support and a bottom belt corresponding to the bottom of the conveyor support. The side belts and bottom belts are staggered along the length of the conveyor support, and the side belts and bottom belts extend along the inner wall of the conveyor support on the side corresponding to the inside of the conveyor support. The inner side of the belt conveyor is provided with a set of conveyor rollers corresponding to the lower edge of one side belt and the side edge of the bottom belt. At both ends of the belt conveyor support, there are steel bar straighteners corresponding to the two sets of conveyor rollers, so as to place the straightened longitudinal bars into the inside of the belt conveyor support through the conveyor rollers. Both the side belt and the bottom belt are equipped with a deflector plate. On the side of the side belt corresponding to the inside of the belt conveyor bracket, the side of the deflector plate corresponding to the top is a flat surface. On one side of the bottom belt corresponding to the inside of the belt conveyor bracket, the side of the deflector plate away from the conveyor roller group is an inclined surface, and a corresponding longitudinal rib is provided on one side of the inclined surface of the deflector plate.

10. The automated processing method for prestressed concrete box girder reinforcement according to claim 9, characterized in that, The gripper includes multiple side rods corresponding to the two side belts and a bottom rod corresponding to the bottom belt. The side rods and bottom rods are respectively hinged with gripping hooks. The side rods and bottom rods are each provided with a crossbar corresponding to the gripping hooks, which slides along the length of the side rods and bottom rods respectively. The gripping hooks are respectively hinged to the crossbars through strip holes, so that they can extend to grip the longitudinal ribs or retract to the outer side of the gripper under the drive of the crossbars.

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