Segmental beam reinforcement frame with turning block and construction auxiliary equipment and method

Abstract

This invention provides a segmental beam reinforcement cage with steering blocks, along with construction auxiliary equipment and methods. The segmental beam reinforcement cage with steering blocks comprises a top reinforcement block composed of multiple horizontal, vertical, and transverse reinforcing bars. This top reinforcement block is a single unit, and its welded end has multiple anchor plates perpendicular to the ends of the reinforcing bars. These anchor plates are riveted to the longitudinal reinforcement bars of the segmental beam reinforcement cage. By changing the anchorage form between the box girder reinforcement and the steering block reinforcement, independent forming of the box girder reinforcement and the steering block reinforcement is achieved. This removes the constraint of the steering block reinforcement on the forming method of the box girder reinforcement, greatly improving the mechanized forming rate of the segmental beam reinforcement, increasing construction efficiency, and reducing labor input.

Description

Technical Field

[0001] This invention relates to the field of segmental beam reinforcement cages, and in particular to a segmental beam reinforcement cage with a deflector block, as well as construction auxiliary equipment and methods. Background Technology

[0002] In modern bridge and building engineering, precast segmental beams are widely used in the construction of large bridges due to their fast construction speed, stable structural quality, and ease of factory production. However, traditional methods face many challenges in the design and manufacturing of the steel reinforcement cage for segmental beams, especially in complex structural sections with steering blocks.

[0003] As a crucial component connecting the reinforcing bars of box girders in different directions, the steering block has a complex internal reinforcing bar network structure. It typically requires manual, synchronized binding and anchoring operations according to detailed design drawings to ensure effective connection and mechanical performance between the reinforcing bars and the main box girder. With continuously rising labor costs, the shortage of skilled workers is becoming increasingly prominent, making this manual labor method unsuitable for the high-efficiency requirements of large-scale industrial production and high-quality engineering projects.

[0004] Furthermore, the positioning accuracy during the splicing of the segmental beam reinforcement cage is also a significant issue. Traditional positioning methods, due to technical limitations and human factors, are prone to large alignment errors between the segmental beam reinforcement cage and the formwork. This not only affects the dimensional accuracy of the structure after concrete pouring but may also pose a potential threat to the overall load-bearing performance and service life of the bridge. Summary of the Invention

[0005] The main objective of this invention is to provide a segmental beam reinforcement cage with a steering block, as well as construction auxiliary equipment and methods. Therefore, in order to overcome the difficulties in the above-mentioned background technology, it is urgent to research and develop more precise and efficient reinforcement cage design and assembly technology, improve the design of the steering block to simplify the reinforcement difficulty, use automated or semi-automated equipment to replace manual binding operations, and develop high-precision positioning technology and devices to achieve the cooperation between the reinforcement cage and the formwork, and ultimately promote the industrialization and modernization of segmental beam precast components.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a segmental beam steel reinforcement skeleton with a steering block, wherein multiple horizontal, vertical and longitudinal steel bars form a top steel reinforcement block of the steering block, the top steel reinforcement block of the steering block is an integral whole, and the welded end of the top steel reinforcement block of the steering block is provided with multiple anchor plates perpendicular to the ends of the steel bars, and the anchor plates are riveted to the longitudinal bars of the segmental beam steel reinforcement skeleton.

[0007] In the preferred embodiment, the structure includes a bottom reinforcing bar block for the steering block, with multiple U-shaped anchor bars on the bottom surface of the bottom reinforcing bar block. A bottom plate reinforcing bar block is located below the bottom reinforcing bar block for the steering block. The multiple U-shaped anchor bars pass through the bottom plate reinforcing bar block and are welded to it to form a whole. The two sides of the bottom plate reinforcing bar block are connected to the web reinforcing bar block through bottom chamfered reinforcing bar blocks. The anchor plate of the top reinforcing bar block for the steering block passes through one side of the web reinforcing bar block and is welded to the inner longitudinal reinforcement of the web reinforcing bar block.

[0008] In the preferred embodiment, the segmental beam reinforcement cage consists of a flange reinforcement block at the top of the web reinforcement block and the top reinforcement block of the turning block. An anchor plate passes through one side of the flange reinforcement block and is riveted to the inner longitudinal reinforcement of the flange reinforcement block. The web reinforcement block is welded to the flange reinforcement block.

[0009] In the preferred embodiment, the flange steel blocks on both sides are connected by the top plate steel blocks.

[0010] In the preferred embodiment, the periphery of the bottom reinforcing bar block of the steering block is a perforated steel plate, and the reinforcing bar at the lower end of the top reinforcing bar block of the steering block passes through the hole in the bottom reinforcing bar block of the steering block and is welded to the bottom reinforcing bar block of the steering block.

[0011] In the preferred embodiment, auxiliary construction equipment is also included: a movable base is provided on the walkway plate on both sides of the outer formwork, the top of the adjusting column on the movable base is hinged to the end of the first electric push rod, the telescopic end of the first electric push rod is provided with a pawl, and a second electric push rod is provided between the cylinder of the first electric push rod and the adjusting column, with both ends of the second electric push rod being hinged to the cylinder of the first electric push rod and the adjusting column, respectively.

[0012] In the preferred embodiment, a visual inspection device is also provided: the shape of the inspection moving frame is set parallel to the inner surface of the outer mold, and multiple visual cameras are provided on the inspection moving frame. An indicator light is provided on one side of each visual camera. The multiple visual cameras are used to inspect the position of the longitudinal reinforcement of the segmental beam steel reinforcement cage.

[0013] In the preferred embodiment, the inspection moving frame moves inside the outer mold via multiple moving wheels. An operating platform is also provided on one side of the inspection moving frame. The bottom of the operating platform is equipped with drive wheels. A monitoring computer is provided on the operating platform. The monitoring computer is electrically connected to multiple vision cameras and indicator lights.

[0014] It also includes an assembly truss, which is movable above the outer formwork, and multiple cranes are located below the assembly truss.

[0015] The method includes:

[0016] S1. According to the design requirements, the top steel reinforcement block of the steering block is prefabricated in the factory. The top steel reinforcement block of the steering block is a whole. The connection between the top steel reinforcement block of the steering block and the flange steel reinforcement block and the web steel reinforcement block is riveted with anchor plates. The anchor plates are clamped on the longitudinal bars of the flange steel reinforcement block and the web steel reinforcement block.

[0017] S2. Use the assembly truss to hoist the bottom plate steel reinforcement blocks to the bottom of the outer formwork. Leave a certain distance between the bottom plate steel reinforcement blocks and the outer formwork. Use the vision camera on the detection moving frame to visually locate and identify the position of the longitudinal reinforcement on the bottom plate steel reinforcement blocks. After the bottom plate steel reinforcement blocks are installed, install the web steel reinforcement blocks.

[0018] S3. The crane assembling the truss lifts the web reinforcement block to one side of the bottom plate reinforcement block. The moving base begins to move to the middle position of the web reinforcement block. The first and second electric push rods control the jaws to clamp one end of the web reinforcement block. The first and second electric push rods and the crane work together to adjust the position of the web reinforcement block. The vision camera on the moving frame visually locates and identifies the position of the longitudinal reinforcement of the web reinforcement block. After the longitudinal reinforcement of the web reinforcement block reaches the preset position, the lower end of the web reinforcement block is welded to the bottom plate reinforcement block. The jaw position remains unchanged. The crane then lifts the bottom chamfered reinforcement block to reinforce the web reinforcement block and the bottom plate reinforcement block through welding.

[0019] S4. The clamping jaws keep the position of the web reinforcement block unchanged. The bottom reinforcement block of the steering block is hoisted to the position above the bottom plate reinforcement block. The bottom reinforcement block of the steering block is installed between the web reinforcement blocks on both sides. The outline of the bottom reinforcement block of the steering block is positioned by a vision camera. The bottom reinforcement block of the steering block is adjusted by at least two cranes. After the position of the bottom reinforcement block of the steering block is adjusted, the bottom reinforcement block of the steering block is welded to the bottom chamfered reinforcement block of the bottom plate reinforcement block.

[0020] S5. The clamping claws keep the position of the web reinforcement block unchanged. The top reinforcement block of the steering block is hoisted to the top of the bottom reinforcement block of the steering block. The vertical bar at the lower end of the top reinforcement block of the steering block is installed in accordance with the hole on the bottom reinforcement block of the steering block. The anchor plate of the top reinforcement block of the steering block is riveted to the longitudinal bar inside the web reinforcement block. One side of the anchor plate is clamped on the longitudinal bar, and then welding is performed. No positioning is required.

[0021] S6. The chuck releases one end of the web reinforcement block, the first and second electric push rods retract, the crane lifts the flange reinforcement block to the top of the top reinforcement block of the steering block and the top of the web reinforcement block, the first and second electric push rods control the chuck to clamp one end of the flange reinforcement block, the first and second electric push rods and the crane adjust the position of the flange reinforcement block, the vision camera on the detection moving frame performs visual positioning and identification of the longitudinal reinforcement position on the flange reinforcement block, after the position is correct, the flange reinforcement block is welded and fixed to the top reinforcement block of the steering block and the web reinforcement block;

[0022] S7. The clamping claws hold the flange steel reinforcement blocks in place, and the crane lifts the top plate steel reinforcement blocks to connect the flange steel reinforcement blocks on both sides. The top plate steel reinforcement blocks and the flange steel reinforcement blocks are then welded and fixed to complete the assembly of the segmental beam steel reinforcement skeleton.

[0023] In the preferred embodiment, the method includes the following steps: the visual camera performs visual positioning and recognition of the longitudinal rib position in steps S2-S7, specifically as follows:

[0024] A1. First, manufacture steel reinforcement blocks according to the design dimensions. A camera at a fixed position captures images of the steel reinforcement blocks. An artificial intelligence vision camera identifies the position of the longitudinal reinforcement bars in the steel reinforcement blocks and converts them into a coordinate array. The coordinate array of the longitudinal reinforcement bar positions is then stored.

[0025] The vision camera is calibrated to determine its parameters;

[0026] Use a calibration board to acquire images at different positions and angles;

[0027] By extracting the world coordinates and pixel coordinates of the calibration board corner points, the initial values ​​of the camera's intrinsic and extrinsic parameters are calculated; then, a nonlinear optimization algorithm and the least squares method are used to optimize the intrinsic and extrinsic parameters to minimize the calibration error.

[0028] The optimized internal and external parameters of the camera are obtained, including the camera matrix and distortion coefficients;

[0029] The camera calibration algorithm is as follows:

[0030]

[0031] Where u and v are pixel coordinates, X, Y, and Z are the visual camera position coordinates, and f x and f y It's the focal length, c x and c y It is the light center;

[0032] Regional brightness filtering is performed as follows: A high-brightness light source is placed around the vision camera to illuminate the end face of the longitudinal rib. Pixels with brightness within a certain range are selected, and contour tracking is performed on the selected area. The steps for regional brightness filtering are: reading the image captured by the camera, performing noise reduction Gaussian filtering on the image, performing histogram equalization on the image, and performing regional brightness filtering based on the brightness threshold. The formula for regional brightness filtering is:

[0033]

[0034] Where I(x, y) is the brightness value of pixel (x, y), and Δx and Δy are the width and height of the region;

[0035] A2. Perform regional brightness filtering on the captured image, that is, select pixels with brightness within a certain range. After selection, perform contour tracking on the selected area, that is, perform vector ellipse fitting on the selected contour. Based on the image of the steel block, perform circular or elliptical filtering on the vector fitting pattern, retain the vector pattern that conforms to the end face of the longitudinal reinforcement, and use the midpoint of the vector pattern as the coordinate array of each longitudinal reinforcement.

[0036] The steps of vector fitting contour tracking are: performing Canny edge detection operator detection on the image after region brightness filtering;

[0037] Perform contour extraction operator on the detected edges;

[0038] Filter the extracted contour using the filtering operator;

[0039] The filtered contour is vectorized to obtain the centroid coordinates and direction vector;

[0040] Among them, the vectorized contour is fitted with an ellipse to obtain the major axis, minor axis and rotation angle of the ellipse;

[0041] Calculate the coordinates of the four vertices of the ellipse based on the coordinates of the center and the lengths of the major and minor axes.

[0042] Based on the end face shape of the longitudinal rib, the coordinates of the four vertices are filtered by a circle or ellipse, retaining the coordinates of the vertices that conform to the end face of the longitudinal rib. The formula for obtaining the midpoint coordinates of the vector pattern using vector fitting is:

[0043]

[0044]

[0045] Where x and y are the coordinates of the midpoint of the vector pattern, A is the radius along the major axis of the ellipse, B is the coordinate along the major axis of the ellipse, C is the coordinate along the minor axis of the ellipse, and D is the product of the coordinates along the major and minor axes of the ellipse; then the formula for fitting the vectors A, B, C, and D is:

[0046]

[0047]

[0048]

[0049]

[0050] Where n is the number of points in the contour, x i and y i These are the coordinates of points on the contour;

[0051] A3. Use the midpoint of the vector pattern as the coordinate array of each longitudinal rib. Use a camera to collect images from the axial direction of the longitudinal rib, detect the position of the longitudinal rib, compare the position coordinates of the longitudinal rib with the design position coordinates, and adjust and correct the position of the longitudinal rib that does not meet the requirements.

[0052] To calculate the actual position coordinates X and Y of the longitudinal reinforcement, it is necessary to first capture an image containing the longitudinal reinforcement and then use the intrinsic and extrinsic parameters obtained from camera calibration to calculate the pixel coordinates u and v.

[0053] Then, we can substitute the pixel coordinates u and v into the position detection formula to calculate the actual position coordinates X and Y of the longitudinal rib.

[0054] We can compare the calculated position coordinates with the design position coordinates to calculate the position accuracy, thereby determining whether the longitudinal reinforcement is in the correct position. The formula for position detection is as follows:

[0055]

[0056]

[0057] Where X and Y are the actual position coordinates of the longitudinal reinforcement, x c and y c These are the design position coordinates, u and v are pixel coordinates, Z is depth information, and f is the depth coordinates. x and f y It's the focal length, c x and c y It is the light center;

[0058] A4. Compare the position coordinates of the longitudinal reinforcement with the design position coordinates, and adjust and correct the positions of the longitudinal reinforcement that do not meet the requirements. The correction formula is:

[0059] ΔX=xX m

[0060] ΔY=yY m

[0061] The actual position coordinates X of the longitudinal reinforcement are obtained from the vision camera. m and Y m Based on the above, the design position coordinates x and y of the longitudinal reinforcement are obtained. The correction amounts ΔX and ΔY are calculated based on the actual position coordinates and the design position coordinates. The crane height, the first electric push rod, and the second electric push rod are controlled according to the correction amounts ΔX and ΔY to adjust the position of the steel reinforcement block.

[0062] Longitudinal reinforcement positions with errors exceeding the preset value range are corrected; while longitudinal reinforcement positions with errors within the preset value range do not require correction.

[0063] This invention provides a segmental beam reinforcement cage with steering blocks, along with construction auxiliary equipment and methods. It solves the problems of complex traditional segmental beam reinforcement design with steering blocks, where the steering block reinforcement and box girder reinforcement are interlocked and anchored, making independent forming impossible. The beneficial effects are:

[0064] Independent Prefabrication and Mechanization Enhancement: By altering the anchorage method of the segmental beam box girder reinforcement and the steering block reinforcement, independent prefabrication and assembly of both are achieved, significantly reducing the process constraints between them. This improvement allows the box girder reinforcement to be independently formed using a more efficient and standardized industrial production process, thereby greatly increasing the mechanization rate of the overall reinforcement skeleton of the segmental beam. This breakthrough not only reduces reliance on skilled workers but also helps improve production efficiency and shorten the construction cycle.

[0065] Construction efficiency and cost optimization: The new anchoring technology reduces the workload and time consumption of manual binding, further improves the construction speed, reduces labor costs, and is conducive to the overall improvement of the project's economic benefits.

[0066] Precision control and quality assurance: Utilizing vision cameras to locate and monitor the position of the turning block reinforcement bars enables precise installation and splicing, ensuring the high precision requirements of the segmental beam reinforcement cage splicing. This not only reduces errors caused by human factors but also improves the dimensional accuracy and mechanical properties of structural components, thereby guaranteeing the safety and durability of the bridge project.

[0067] Adapting to the needs of modern construction: The above-mentioned technological innovations actively respond to the requirements of modern high-quality engineering construction for efficient, precise, and automated production, effectively promote the progress of bridge construction technology, and provide a reference for the industrial manufacturing of similar complex structures. Attached Figure Description

[0068] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0069] Figure 1 This is a structural diagram showing the disassembled reinforcement cage of the segmental beam of the present invention;

[0070] Figure 2 This is a structural diagram of the segmental beam steel reinforcement skeleton of the steering block of the present invention;

[0071] Figure 3 This is a structural diagram of the segmental beam reinforcement skeleton splicing web reinforcement block of the present invention;

[0072] Figure 4 This is a structural diagram of the top reinforcing bar block of the segmental beam reinforcing bar skeleton splicing turning block of the present invention;

[0073] Figure 5 This is a structural diagram of the segmental beam reinforcement skeleton splicing flange reinforcement block of the present invention;

[0074] Figure 6 This is a structural diagram of the segmental beam reinforcement skeleton splicing top slab reinforcement block of the present invention;

[0075] Figure 7 This is a structural diagram of the detection moving frame and the longitudinal reinforcement bars of the present invention;

[0076] Figure 8 This is a diagram of the installation structure of the mobile testing frame of the present invention;

[0077] Figure 9 This is the main view of the installation structure of the mobile testing frame of the present invention;

[0078] Figure 10 This is a schematic diagram of the overall structure of the mobile detection frame of the present invention;

[0079] Figure 11 This is a structural diagram showing the installation position of the detection mobile frame and the longitudinal reinforcement bars of the present invention.

[0080] In the diagram: 1. Top plate reinforcing bar block; 2. Flange reinforcing bar block; 3. Top reinforcing bar block of steering block; 301. Anchor plate; 4. Web plate reinforcing bar block; 5. Bottom reinforcing bar block of steering block; 501. U-shaped anchor bar; 6. Bottom plate reinforcing bar block; 7. Bottom chamfered reinforcing bar block; 8. Outer formwork; 9. Assembly truss; 901. Crane; 10. First electric push rod; 11. Second electric push rod; 12. Moving base; 13. Claw; 14. Detection moving frame; 1401. Moving wheel; 15. Vision camera; 16. Indicator light; 17. Operating platform; 18. Drive wheel; 19. Monitoring computer; 20. Longitudinal reinforcing bar. Detailed Implementation

[0081] Example 1

[0082] like Figures 1-11As shown, a segmental beam reinforcement skeleton with a turning block is provided. Multiple horizontal, vertical, and transverse reinforcing bars form the top reinforcing bar block 3 of the turning block. The top reinforcing bar block 3 is a single unit. Multiple anchor plates 301 perpendicular to the ends of the reinforcing bars are provided at the welded ends of the top reinforcing bar block 3. The anchor plates 301 are riveted to the longitudinal reinforcing bars of the segmental beam reinforcement skeleton. The skeleton also includes a bottom reinforcing bar block 5, with multiple U-shaped anchor bars 501 on its bottom surface. A bottom plate reinforcing bar block 6 is located below the bottom reinforcing bar block 5. The multiple U-shaped anchor bars 501 pass through the bottom plate reinforcing bar block 6 and are welded to it to form a single unit. The two sides of the bottom plate reinforcing bar block 6 are connected to the web reinforcing bar block 4 via bottom chamfered reinforcing bar blocks 7. The anchor plates 301 of the top reinforcing bar block 3 pass through the web reinforcing bar block 4 and are welded to the inner longitudinal reinforcing bars of the web reinforcing bar block 4. By changing the anchorage form of the segmental beam box reinforcement and the turning block reinforcement, the independent forming of the box reinforcement and the turning block reinforcement is achieved. This removes the constraint of the turning block reinforcement on the forming method of the box reinforcement, greatly improves the mechanized forming rate of the segmental beam reinforcement, enhances construction efficiency, and reduces labor input.

[0083] In the preferred embodiment, the segmental beam reinforcement skeleton consists of a flange reinforcement block 2 at the top of the web reinforcement block 4 and the top reinforcement block 3 of the turning block. An anchor plate 301 passes through one side of the flange reinforcement block 2 and is riveted to the longitudinal reinforcement inside the flange reinforcement block 2. The web reinforcement block 4 is welded to the flange reinforcement block 2.

[0084] In the preferred embodiment, the flange steel bars 2 on both sides are connected by the top plate steel bars 1.

[0085] In the preferred embodiment, the bottom reinforcing bar block 5 of the steering block is surrounded by a perforated steel plate, and the reinforcing bar at the lower end of the top reinforcing bar block 3 of the steering block passes through the hole in the bottom reinforcing bar block 5 of the steering block and is welded to the bottom reinforcing bar block 5 of the steering block.

[0086] The mechanized forming methods include: from unit parts to mesh sheets, then bending the whole into a block; or processing unit parts into closed hoops, then inserting main reinforcement bars.

[0087] The bottom reinforcing bars and the top reinforcing bars of the steering block are independent of each other, and are assembled to form a reinforcing bar skeleton for the steering block.

[0088] The bottom reinforcing bars of the bottom reinforcing bar block of the steering block are welded to the open steel plate to form a whole, and then anchored and assembled with the box body reinforcing bars by U-shaped anchor bars.

[0089] The steel bars of the top steel bar block of the steering block have end anchor plates. In order to facilitate the assembly of the top steel bar block, the vertical bars of the top steel bar block of the steering block are changed from an inclined state to a vertical state, provided that the stress meets the specification requirements.

[0090] The mutual anchoring method between the box-type steel bars and the turning block steel bars is changed. By using anchor blocks and anchor plates, the independent forming and combined assembly of the box-type steel bars and the turning block steel bars can be achieved.

[0091] The box-shaped steel reinforcement includes one bottom slab steel reinforcement block, two chamfered steel reinforcement blocks, two web steel reinforcement blocks, two flange steel reinforcement blocks, and one top slab steel reinforcement block.

[0092] The steering block reinforcement includes one bottom steering block reinforcement block and two top steering block reinforcement blocks.

[0093] The bottom plate steel reinforcement blocks, chamfered steel reinforcement blocks, web steel reinforcement blocks, flange steel reinforcement blocks, and top plate steel reinforcement blocks have similar shapes and sizes, and can be mechanically formed using equipment.

[0094] The mechanized forming methods include: from unit parts to mesh sheets, then bending the whole into a block; or processing unit parts into closed hoops, then inserting main reinforcement bars.

[0095] In the preferred embodiment, auxiliary construction equipment is also included: a movable base 12 is provided on the walkway plates on both sides of the outer mold 8; the top of the adjusting column on the movable base 12 is hinged to the end of the first electric push rod 10; the telescopic end of the first electric push rod 10 is provided with a claw 13; a second electric push rod 11 is provided between the cylinder of the first electric push rod 10 and the adjusting column; the two ends of the second electric push rod 11 are respectively hinged to the cylinder of the first electric push rod 10 and the adjusting column. The movable base 12 is installed on the walkway plates on both sides of the outer mold 8, serving as the basic support platform for the entire adjustment mechanism.

[0096] The cylinder of the first electric push rod 10 is hinged to the top of the adjusting column. This design allows the first electric push rod 10 to change angles during its extension and retraction to adapt to position adjustment needs in different directions and heights. The telescopic end of the first electric push rod 10 is equipped with a claw 13, which is used to directly contact, fix, or move the reinforcing bar block, thereby achieving precise positioning and adjustment of the reinforcing bar block's position. A second electric push rod 11 is added between the first electric push rod 10 and the adjusting column, with its two ends hinged to the cylinder of the first electric push rod 10 and the adjusting column, respectively. This means that the second electric push rod 11 can independently change the angle of the first electric push rod 10, further increasing its degrees of freedom of movement, allowing the device to adjust the position of the reinforcing bar block from more dimensions. The crane 901 works in conjunction with the electric push rods. The crane may be responsible for overall lifting and initial positioning of the reinforcing bar block, while the electric push rods are responsible for fine-tuning and fixing it in place. Their collaborative operation ensures high-precision installation of the reinforcing bar block in three-dimensional space.

[0097] In the preferred embodiment, a visual inspection device is also included: the inspection moving frame 14 is arranged parallel to the inner surface of the outer mold 8, and multiple visual cameras 15 are mounted on the inspection moving frame 14. Each visual camera 15 has an indicator light 16 on one side. The multiple visual cameras 15 are used to detect the position of the longitudinal reinforcement in the segmental beam's steel reinforcement cage. In this structural description, the design of the inspection moving frame 14, which is parallel to the inner surface of the outer mold 8, ensures accurate monitoring of the internal space of the segmental beam. The inspection moving frame 14 is equipped with multiple visual cameras 15, which have high-precision image acquisition and processing capabilities. Their main function is to perform real-time and accurate detection of the position of the longitudinal reinforcement in the segmental beam's steel reinforcement cage.

[0098] The vision camera 15 can capture detailed image information of the segmental beam reinforcement cage and accurately locate the position of each longitudinal bar through built-in or supporting image recognition algorithms. When the vision camera detects a deviation in the position of the longitudinal bar, the indicator light 16 on one side will provide immediate feedback, prompting the operator to check the current detection status by lighting up or changing color, so as to make timely adjustments and corrections to ensure that the installation accuracy of the segmental beam reinforcement cage meets the design requirements.

[0099] When the longitudinal reinforcement reaches the preset position, indicator light 16 will turn green; otherwise, it will turn red.

[0100] The application of this technology has greatly improved the automation and quality control level of the segmental beam construction process, reduced errors caused by manual measurement, and provided reliable quality assurance for subsequent concrete pouring.

[0101] In the preferred embodiment, the inspection moving frame 14 moves inside the outer mold 8 via multiple moving wheels 1401. An operating platform 17 is also provided on one side of the inspection moving frame 14. A drive wheel 18 is provided at the bottom of the operating platform 17. A monitoring computer 19 is provided on the operating platform 17. The monitoring computer 19 is electrically connected to multiple vision cameras 15 and indicator lights 16.

[0102] It also includes an assembly truss 9, which is movable above the outer mold 8, and multiple cranes 901 are located below the assembly truss 9.

[0103] Example 2

[0104] Further explanation in conjunction with Example 1, such as Figure 1-11 As shown in the structure, S1, according to the design requirements, the top steel reinforcement block 3 of the steering block is prefabricated in the factory. The top steel reinforcement block 3 of the steering block is a whole. The connection position of the top steel reinforcement block 3 of the steering block with the flange steel reinforcement block 2 and the web steel reinforcement block 4 is riveted with the anchor plate 301. The anchor plate 301 is stuck on the longitudinal reinforcement of the flange steel reinforcement block 2 and the web steel reinforcement block 4.

[0105] S2. Use the assembly truss 9 to hoist the bottom plate steel reinforcement block 6 to the bottom of the outer formwork 8. There is a certain distance between the bottom plate steel reinforcement block 6 and the outer formwork 8. The vision camera 15 on the detection moving frame 14 performs visual positioning and identification of the longitudinal reinforcement position on the bottom plate steel reinforcement block 6. After the bottom plate steel reinforcement block 6 is installed, the web steel reinforcement block 4 is installed.

[0106] S3. The crane 901 of the assembling truss 9 lifts the web plate steel reinforcement block 4 to one side of the bottom plate steel reinforcement block 6. The moving base 12 begins to move to the middle position of the web plate steel reinforcement block 4. The first electric push rod 10 and the second electric push rod 11 control the claw 13 to clamp one end of the web plate steel reinforcement block 4. The first electric push rod 10, the second electric push rod 11 and the crane 901 jointly adjust the position of the web plate steel reinforcement block 4. The vision camera 15 on the detection moving frame 14 performs visual positioning and identification of the longitudinal reinforcement position of the web plate steel reinforcement block 4. After the longitudinal reinforcement of the web plate steel reinforcement block 4 reaches the preset position, the lower end of the web plate steel reinforcement block 4 is welded to the bottom plate steel reinforcement block 6. The position of the control claw 13 remains unchanged. The crane 901 then lifts the bottom chamfered steel reinforcement block 7 to reinforce the welding of the web plate steel reinforcement block 4 and the bottom plate steel reinforcement block 6.

[0107] S4. The chuck 13 clamps the web plate steel reinforcement block 4 in place, and the bottom steel reinforcement block 5 of the steering block is hoisted to a position above the bottom plate steel reinforcement block 6. The bottom steel reinforcement block 5 of the steering block is installed between the two web plate steel reinforcement blocks 4. The outline of the bottom steel reinforcement block 5 of the steering block is positioned by the vision camera 15. The bottom steel reinforcement block 5 of the steering block is adjusted by at least two cranes 901. After the position of the bottom steel reinforcement block 5 of the steering block is adjusted, the bottom steel reinforcement block 5 of the steering block is welded to the bottom chamfered steel reinforcement block 7 of the bottom plate steel reinforcement block 6.

[0108] S5, the chuck 13 clamps and keeps the position of the web plate steel reinforcement block 4 unchanged. The top steel reinforcement block 3 of the steering block is hoisted to the top of the bottom steel reinforcement block 5 of the steering block. The vertical bar at the lower end of the top steel reinforcement block 3 of the steering block is installed in accordance with the hole on the bottom steel reinforcement block 5 of the steering block. The anchor plate 301 of the top steel reinforcement block 3 of the steering block is riveted to the longitudinal bar inside the web plate steel reinforcement block 4. One side of the anchor plate 301 is clamped on the longitudinal bar and then welded. No positioning is required.

[0109] S6. The chuck 13 releases one end of the web reinforcement block 4, and the first electric push rod 10 and the second electric push rod 11 retract. The crane 901 lifts the flange reinforcement block 2 to the top of the top reinforcement block 3 and the web reinforcement block 4 of the steering block. The first electric push rod 10 and the second electric push rod 11 control the chuck 13 to clamp one end of the flange reinforcement block 2. The first electric push rod 10, the second electric push rod 11 and the crane 901 adjust the position of the flange reinforcement block 2. The vision camera 15 on the detection moving frame 14 performs visual positioning and identification of the longitudinal reinforcement position on the flange reinforcement block 2. After the position is correct, the flange reinforcement block 2 is welded and fixed to the top reinforcement block 3 and the web reinforcement block 4 of the steering block.

[0110] S7, the clamp 13 clamps the flange steel bar block 2 in the same position, the crane 901 lifts the top plate steel bar block 1 and connects the flange steel bar blocks 2 on both sides, the top plate steel bar block 1 and the flange steel bar block 2 are welded and fixed to complete the assembly of the segmental beam steel bar skeleton;

[0111] Example 3

[0112] Further explanation in conjunction with Example 2, such as Figure 1-11 The structure shown in the figure, the specific steps of the vision camera 15 in steps S2-S7 for visually locating and identifying the position of the longitudinal rib are as follows:

[0113] A1. First, fabricate steel reinforcement blocks according to the design dimensions. A camera at a fixed position captures images of the steel reinforcement blocks. The position of the longitudinal reinforcement in the steel reinforcement blocks is identified by the artificial intelligence vision camera 15 and converted into a coordinate array. The coordinate array of the longitudinal reinforcement positions is then stored.

[0114] The vision camera 15 is calibrated to determine its parameters;

[0115] Use a calibration board to acquire images at different positions and angles;

[0116] By extracting the world coordinates and pixel coordinates of the calibration board corner points, the initial values ​​of the camera's intrinsic and extrinsic parameters are calculated; then, a nonlinear optimization algorithm and the least squares method are used to optimize the intrinsic and extrinsic parameters to minimize the calibration error.

[0117] The optimized internal and external parameters of the camera are obtained, including the camera matrix and distortion coefficients;

[0118] The camera calibration algorithm is as follows:

[0119]

[0120] Where u and v are pixel coordinates, X, Y, and Z are the position coordinates of the visual camera 15, and f x and f y It's the focal length, c x and cy It is the light center;

[0121] Regional brightness filtering is performed as follows: A high-brightness light source is placed around the visual camera 15 to illuminate the end face of the longitudinal rib. Pixels with brightness within a certain range are selected. After selection, contour tracking is performed on the selected area. The steps for regional brightness filtering are: reading the image captured by the camera, performing noise reduction Gaussian filtering on the image, performing histogram equalization on the image, and performing regional brightness filtering based on the brightness threshold. The formula for regional brightness filtering is:

[0122]

[0123] Where I(x, y) is the brightness value of pixel (x, y), and Δx and Δy are the width and height of the region;

[0124] A2. Perform regional brightness filtering on the captured image, that is, select pixels with brightness within a certain range. After selection, perform contour tracking on the selected area, that is, perform vector ellipse fitting on the selected contour. Based on the image of the steel block, perform circular or elliptical filtering on the vector fitting pattern, retain the vector pattern that conforms to the end face of the longitudinal reinforcement, and use the midpoint of the vector pattern as the coordinate array of each longitudinal reinforcement.

[0125] The steps of vector fitting contour tracking are: performing Canny edge detection operator detection on the image after region brightness filtering;

[0126] Perform contour extraction operator on the detected edges;

[0127] Filter the extracted contour using the filtering operator;

[0128] The filtered contour is vectorized to obtain the centroid coordinates and direction vector;

[0129] Among them, the vectorized contour is fitted with an ellipse to obtain the major axis, minor axis and rotation angle of the ellipse;

[0130] Calculate the coordinates of the four vertices of the ellipse based on the coordinates of the center and the lengths of the major and minor axes.

[0131] Based on the end face shape of the longitudinal rib, the coordinates of the four vertices are filtered by a circle or ellipse, retaining the coordinates of the vertices that conform to the end face of the longitudinal rib. The formula for obtaining the midpoint coordinates of the vector pattern using vector fitting is:

[0132]

[0133]

[0134] Where x and y are the coordinates of the midpoint of the vector pattern, A is the radius along the major axis of the ellipse, B is the coordinate along the major axis of the ellipse, C is the coordinate along the minor axis of the ellipse, and D is the product of the coordinates along the major and minor axes of the ellipse; then the formula for fitting the vectors A, B, C, and D is:

[0135]

[0136]

[0137]

[0138]

[0139] Where n is the number of points in the contour, x i and y i These are the coordinates of points on the contour;

[0140] A3. Use the midpoint of the vector pattern as the coordinate array of each longitudinal rib. Use a camera to collect images from the axial direction of the longitudinal rib, detect the position of the longitudinal rib, compare the position coordinates of the longitudinal rib with the design position coordinates, and adjust and correct the position of the longitudinal rib that does not meet the requirements.

[0141] To calculate the actual position coordinates X and Y of the longitudinal reinforcement, it is necessary to first capture an image containing the longitudinal reinforcement and then use the intrinsic and extrinsic parameters obtained from camera calibration to calculate the pixel coordinates u and v.

[0142] Then, we can substitute the pixel coordinates u and v into the position detection formula to calculate the actual position coordinates X and Y of the longitudinal rib.

[0143] We can compare the calculated position coordinates with the design position coordinates to calculate the position accuracy, thereby determining whether the longitudinal reinforcement is in the correct position. The formula for position detection is as follows:

[0144]

[0145]

[0146] Where X and Y are the actual position coordinates of the longitudinal reinforcement, x c and y c These are the design position coordinates, u and v are pixel coordinates, Z is depth information, and f is the depth coordinates. x and f y It's the focal length, c x and c y It is the light center;

[0147] A4. Compare the position coordinates of the longitudinal reinforcement with the design position coordinates, and adjust and correct the positions of the longitudinal reinforcement that do not meet the requirements. The correction formula is:

[0148] ΔX=xX m

[0149] ΔY=yY m

[0150] The actual position coordinates X of the longitudinal reinforcement are obtained from the vision camera 15. m and Y m Based on the above, the design position coordinates x and y of the longitudinal reinforcement are obtained. The correction amount ΔX and ΔY are calculated based on the actual position coordinates and the design position coordinates. Based on the correction amount ΔX and ΔY, the height of the crane 901, the first electric push rod 10 and the second electric push rod 11 are controlled to adjust the position of the steel reinforcement block.

[0151] Longitudinal reinforcement positions with errors exceeding the preset value range are corrected; while longitudinal reinforcement positions with errors within the preset value range do not require correction.

[0152] The above embodiments are merely preferred technical solutions of the present invention and should not be regarded as limitations on the present invention. The scope of protection of the present invention should be the technical solution 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 construction method for a segmental beam reinforcement cage with steering blocks, characterized in that: The segmental beam reinforcement cage includes a top reinforcement block (3) and a bottom reinforcement block (5) of the steering block; Multiple horizontal, vertical and vertical steel bars form the top steel bar block (3) of the turning block. The top steel bar block (3) of the turning block is a whole. The welded end of the top steel bar block (3) of the turning block is provided with multiple anchor plates (301) perpendicular to the ends of the steel bars. The walkway plates on both sides of the outer mold (8) are provided with movable bases (12). The top of the adjusting column on the movable base (12) is hinged to the end of the first electric push rod (10). The telescopic end of the first electric push rod (10) is provided with a claw (13). A second electric push rod (11) is provided between the cylinder of the first electric push rod (10) and the adjusting column. The two ends of the second electric push rod (11) are respectively hinged to the cylinder of the first electric push rod (10) and the adjusting column. The outer mold (8) is equipped with a detection moving frame (14); The construction method includes: S1. According to the design requirements, the top steel reinforcement block (3) of the steering block is prefabricated in the factory. The top steel reinforcement block (3) of the steering block is formed as a whole. The connection position of the top steel reinforcement block (3) of the steering block with the flange steel reinforcement block (2) and the web steel reinforcement block (4) is riveted with the anchor plate (301). The anchor plate (301) is stuck on the longitudinal reinforcement of the flange steel reinforcement block (2) and the web steel reinforcement block (4). S2. Using the assembly truss (9), the bottom plate steel reinforcement block (6) is hoisted to the bottom of the outer formwork (8). There is a distance between the bottom plate steel reinforcement block (6) and the outer formwork (8). The vision camera (15) on the detection moving frame (14) performs visual positioning and identification of the longitudinal reinforcement position on the bottom plate steel reinforcement block (6). After the bottom plate steel reinforcement block (6) is installed, the web steel reinforcement block (4) is installed. S3. The crane (901) assembling the truss (9) lifts the web reinforcement block (4) to one side of the bottom plate reinforcement block (6). The moving base (12) begins to move to the middle position of the web reinforcement block (4). The first electric push rod (10) and the second electric push rod (11) control the jaws (13) to clamp one end of the web reinforcement block (4). The first electric push rod (10), the second electric push rod (11) and the crane (901) work together to adjust the web reinforcement block (4). The position of the web reinforcement block (4) is detected by the visual camera (15) on the moving frame (14). After the longitudinal reinforcement of the web reinforcement block (4) reaches the preset position, the lower end of the web reinforcement block (4) is welded to the bottom plate reinforcement block (6). The position of the control claw (13) remains unchanged. The crane (901) then lifts the bottom chamfered reinforcement block (7) to reinforce the web reinforcement block (4) and the bottom plate reinforcement block (6). S4. The chuck (13) clamps the web plate steel reinforcement block (4) in place, and lifts the bottom steel reinforcement block (5) of the steering block to the position above the bottom plate steel reinforcement block (6). The bottom steel reinforcement block (5) of the steering block is installed between the two web plate steel reinforcement blocks (4). The outline of the bottom steel reinforcement block (5) of the steering block is positioned by the vision camera (15). The bottom steel reinforcement block (5) of the steering block is adjusted by at least two cranes (901). After the position of the bottom steel reinforcement block (5) of the steering block is adjusted, the bottom steel reinforcement block (5) of the steering block is welded to the bottom plate steel reinforcement block (6) and the bottom chamfered steel reinforcement block (7). S5. The chuck (13) clamps the web plate steel reinforcement block (4) in place. The top steel reinforcement block (3) of the steering block is hoisted to the top of the bottom steel reinforcement block (5) of the steering block. The vertical bar at the bottom of the top steel reinforcement block (3) of the steering block is installed in accordance with the hole on the bottom steel reinforcement block (5) of the steering block. The anchor plate (301) of the top steel reinforcement block (3) of the steering block is riveted to the longitudinal bar inside the web plate steel reinforcement block (4). One side of the anchor plate (301) is clamped on the longitudinal bar and then welded. No positioning is required. S6. The chuck (13) releases one end of the web reinforcement block (4), the first electric push rod (10) and the second electric push rod (11) retract, the crane (901) lifts the flange reinforcement block (2) to the top of the top reinforcement block (3) and the web reinforcement block (4) of the steering block, the first electric push rod (10) and the second electric push rod (11) control the chuck (13) to clamp one end of the flange reinforcement block (2), the first electric push rod (10) and the second electric push rod (11) and the crane (901) adjust the position of the flange reinforcement block (2), the vision camera (15) on the detection moving frame (14) performs visual positioning and identification of the longitudinal reinforcement position on the flange reinforcement block (2), after the position is correct, the flange reinforcement block (2) is welded and fixed to the top reinforcement block (3) and the web reinforcement block (4) of the steering block; S7. The chuck (13) clamps the flange steel bar block (2) in the same position. The crane (901) lifts the top plate steel bar block (1) and connects the flange steel bar blocks (2) on both sides. The top plate steel bar block (1) and the flange steel bar block (2) are welded and fixed to complete the assembly of the segmental beam steel bar skeleton.

2. The construction method of the segmental beam reinforcement cage with steering blocks according to claim 1, characterized in that: The bottom surface of the bottom steel bar block (5) of the steering block is provided with multiple U-shaped anchor bars (501). The bottom steel bar block (5) of the steering block is provided with a bottom plate steel bar block (6). Multiple U-shaped anchor bars (501) pass through the bottom plate steel bar block (6) and are welded to the bottom plate steel bar block (6) to form a whole. The bottom plate steel bar block (6) is connected to the web steel bar block (4) on both sides through the bottom chamfered steel bar block (7). The anchor plate (301) of the top steel bar block (3) of the steering block passes through the web steel bar block (4) and is welded to the inner longitudinal bar of the web steel bar block (4).

3. The construction method of the segmental beam reinforcement cage with steering blocks according to claim 1, characterized in that: The top of the web reinforcement block (4) and the top reinforcement block (3) of the turning block are provided with flange reinforcement blocks (2). The anchor plate (301) passes through the flange reinforcement block (2) and is riveted to the longitudinal reinforcement inside the flange reinforcement block (2). The web reinforcement block (4) is welded to the flange reinforcement block (2).

4. The construction method of the segmental beam reinforcement cage with steering blocks according to claim 2, characterized in that: The bottom reinforcing bar block (5) of the steering block is surrounded by a perforated steel plate. The reinforcing bar at the lower end of the top reinforcing bar block (3) of the steering block passes through the hole of the bottom reinforcing bar block (5) of the steering block and is welded to the bottom reinforcing bar block (5) of the steering block.

5. The construction method of the segmental beam reinforcement cage with steering blocks according to claim 1, characterized in that: The inspection moving frame (14) is set parallel to the inner surface of the outer mold (8). Multiple vision cameras (15) are provided on the inspection moving frame (14). Each vision camera (15) has an indicator light (16) on one side. The multiple vision cameras (15) are used to detect the position of the longitudinal reinforcement of the segmental beam steel reinforcement skeleton.

6. The construction method of the segmental beam reinforcement cage with steering blocks according to claim 5, characterized in that: The detection mobile frame (14) moves inside the outer mold (8) via multiple moving wheels (1401). An operating platform (17) is also provided on one side of the detection mobile frame (14). A drive wheel (18) is provided at the bottom of the operating platform (17). A monitoring computer (19) is provided on the operating platform (17). The monitoring computer (19) is electrically connected to multiple vision cameras (15) and indicator lights (16). The assembly truss (9) is movable above the outer mold (8), and multiple cranes (901) are provided below the assembly truss (9).

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