Industrialized intelligent production method and equipment for cast-in-place box girder steel bar components

Abstract

The present invention provides an industrialized intelligent manufacturing method and equipment for cast-in-situ box girder steel bar components, which manufactures steel bar units and assembles them into steel meshes; the steel meshes are arranged vertically and placed in a mesh frame; the longitudinal bars are arranged according to the design dimensions; the longitudinal bars are inserted into multiple steel meshes in the longitudinal direction; the longitudinal bars are connected to the first steel mesh; the longitudinal bars are pulled to continue to move for a distance, the moving distance being the same as the spacing between the steel meshes; the longitudinal bars are connected to the second steel mesh; and the above steps are repeated until all the steel meshes are connected to the longitudinal bars; the industrialized manufacturing of steel blocks in the steel bar components is achieved through the above steps. The assembly of the steel mesh is completed on a steel mesh forming platform, and a mobile welding device is also provided for welding the steel bar units to form a steel mesh. The present invention provides an industrialized intelligent manufacturing method and equipment for cast-in-situ box girder steel bar components, which produces cast-in-situ box girder steel bar components in an industrialized and intelligent manner.

Description

Technical Field

[0001] The present invention relates to the technical field of bridge beam steel bar structure forming, and in particular to an industrialized intelligent production method and equipment for cast-in-situ box beam steel bar components. Background Art

[0002] Transportation plays an increasingly important role in China's economic development, and bridges are an essential component of transportation infrastructure. As bridge construction technology matures, reinforced concrete box girders are trending toward larger, longer, and wider structures. The resulting steel reinforcement is also growing larger and heavier, making the construction of each span labor-intensive and difficult to maintain. At box girder reinforcement construction sites, the most common method is to manually move the steel bars into the outer formwork for positioning, tying, or welding. This is inefficient and makes it difficult to maintain a guaranteed production schedule. Due to the large size of the box girders, the labor-intensive process requires significant manpower, increasing safety risks on the construction site. Because construction sites often operate outdoors, reinforcement construction is susceptible to inclement weather, resulting in construction hiatuses. Furthermore, due to limited worker skill, the quality of the box girder reinforcement is difficult to ensure. Current cast-in-place box girder construction processes and methods lack a high degree of mechanization and automation, making quality control difficult. Therefore, it is necessary to introduce the industrialized construction concept of "factory production and assembly construction", introduce the industrial construction method into the construction of cast-in-place box girders, and place most of the box girder reinforcement structure in the factory for production. The construction site only needs to perform simple assembly and shaping to complete the production of the entire span reinforcement structure. Patent document CN112123564A is a method for producing reinforcement components for segmental assembly of concrete box girders. It adopts an assembly scheme, but the scheme has the problem that the mesh size is too large and it is difficult to transport. Moreover, due to the lack of sufficient rigidity of the mesh, it is easy to deform during transportation and hoisting. There is also the problem of high difficulty in on-site assembly and overall bending. In CN209521081U, a scheme for a meshed steel skeleton cage for small box girders, it is recorded that the steel bars are first welded into a steel mesh, and then the steel mesh is bent and then welded into a whole. The problem is that the steel mesh after welding is difficult to process again, and it is difficult to obtain a shape that meets the design requirements. Moreover, during the bending process, the welded position is prone to breakage and desoldering. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide an industrialized intelligent production method and equipment for cast-in-place box girder steel bar components, which can significantly improve the industrialization and intelligence of box girder steel bar components and significantly improve the efficiency, quality and safety of cast-in-place box girder steel bar construction. The steel mesh can be made into blocks with dimensions that meet design requirements and then assembled in a warehouse, with high processing precision and reliable quality. The number of personnel at large box girder construction sites can be significantly reduced, reducing safety risks. It can solve the problem of intelligent, automated and industrialized production of steel bar blocks, which have the largest number of welds and the greatest processing difficulty.

[0004] To solve the above technical problems, the technical solution of the present invention is: an industrialized intelligent production method for cast-in-situ box girder steel bar components, comprising the following steps:

[0005] S1. Make steel bar units according to the design dimensions and assemble them into steel mesh;

[0006] S2. Arrange multiple steel mesh sheets vertically and place them into the mesh frame;

[0007] S3. Arrange the longitudinal reinforcement according to the design dimensions;

[0008] S4, insert the longitudinal reinforcement into multiple steel meshes along the longitudinal direction;

[0009] S5. Connect the longitudinal reinforcement to the first steel mesh;

[0010] S6. The longitudinal reinforcement is pulled to continue to move for a distance, the distance of which is the same as the spacing between the steel meshes;

[0011] S7, connecting the longitudinal reinforcement to the second steel mesh;

[0012] S8. Repeat steps S6 to S7 until all the steel meshes are connected to the longitudinal bars;

[0013] The above steps enable the industrialized production of steel bar blocks in steel bar components.

[0014] In a preferred embodiment, in step S1, the steel mesh is assembled on a steel mesh forming platform. A plurality of steel bar positioning fixtures are provided on the steel mesh forming platform. The shaped steel bar units are placed on the steel mesh forming platform and fixed by the steel bar positioning fixtures.

[0015] A mobile welding device is also provided, and the mobile welding device is provided with an identification device for identifying the positions of welding points between steel bar units according to design requirements.

[0016] In a preferred embodiment, in step S2, the top surface and one end of the mesh frame are open, and the other end is limited to the steel mesh, but can allow the arranged longitudinal bars to pass through, and the longitudinal bars located at the bottom layer pass through the inner side of the steel mesh;

[0017] Sliding mesh positioning claws are provided on both sides of the mesh frame, and at least one positioning mechanism is provided on the mesh positioning claws for fixing the first steel mesh;

[0018] The mesh frame is also provided with a mesh position acquisition camera for acquiring the position of the steel mesh currently located at the first position, so that the positioning mechanism can fix the steel mesh currently located at the first position.

[0019] In a preferred solution, in step S3, the bundled longitudinal bars are shaken out and loaded individually in a width-limited single-bar loading manner;

[0020] Two layers of longitudinal reinforcement slides are provided, and longitudinal reinforcement positioning grooves corresponding to the installation positions of the longitudinal reinforcements are provided on the longitudinal reinforcement slides;

[0021] Below the feeding mechanism and above the longitudinal bar carriage, a retractable bar-dropping telescopic arm is provided to drop each longitudinal bar into each longitudinal bar positioning slot by dropping the end thereof; alternatively, two articulated robotic arms are provided to deliver each longitudinal bar into each longitudinal bar positioning slot by lifting the material;

[0022] After one layer of longitudinal reinforcement carriage is fully loaded, switch to another layer of longitudinal reinforcement carriage to continue paving;

[0023] Through the above method, the longitudinal reinforcement can be arranged according to the design size.

[0024] In a preferred solution, in step S4, the two layers of longitudinal reinforcement slides are moved simultaneously, so that the ends of the longitudinal reinforcements pass through the mesh frame and the steel mesh and are connected to the longitudinal reinforcement traction device, and the longitudinal reinforcements are pulled by the longitudinal reinforcement traction device to move.

[0025] In a preferred embodiment, in steps S5 to S7, a block welding device is provided between the longitudinal reinforcement pulling device and the mesh frame, and the block welding device is used to weld the longitudinal reinforcement to the steel mesh.

[0026] In a preferred solution, an identification device is provided on the block welding device for identifying the positions of the welding points between the steel bar units according to design requirements.

[0027] In the preferred solution, the recognition device adopts a dual-camera visual positioning recognition method with a specific spacing, binarizes the collected dual-camera images respectively, marks the intersection position within the current field of view working range, and uses the visual difference of the dual-camera images combined with trigonometric functions to calculate the intersection position coordinates, and compares the intersection position coordinates with the design coordinates. When the error value is within the preset range, welding is performed at the intersection position. If the error value exceeds the preset range, the current welding point is skipped, the next welding point is processed, and an alarm is issued.

[0028] In a preferred solution, the recognition device adopts a single-camera visual positioning recognition method, the block welding head of the block welding device is driven by a Cartesian coordinate mechanism, the block welding device moves longitudinally, the recognition device feeds back the image of the steel mesh so that the block welding head is aligned with the steel mesh located at the first position, the block welding carriage of the block welding device moves transversely, the recognition device feeds back the image of the current longitudinal reinforcement so that the block welding head is aligned with the current longitudinal reinforcement, and the block welding head welds the longitudinal reinforcement of the first layer to the steel mesh;

[0029] According to the design size, the block welding head is controlled to drop a certain distance, and the block welding head welds the longitudinal reinforcement of the second layer to the steel mesh;

[0030] The recognition device detects whether there is a red hot spot of welding in the image, and whether the red hot spot is located at the intersection between the longitudinal reinforcement and the steel mesh, and provides feedback on the welding quality.

[0031] In a preferred solution, the longitudinal reinforcement traction device moves along the traction guide rail, and the longitudinal reinforcement traction device is tractioned by a one-way locking device and a traction cylinder. The one-way locking device is used to lock the longitudinal reinforcement traction device on the traction guide rail in one direction, and the traction cylinder is a hydraulic cylinder or a pneumatic cylinder, which is used to drag the entire longitudinal reinforcement traction device and the longitudinal reinforcement to move;

[0032] A travel sensor is also provided on the longitudinal reinforcement traction device to detect the travel distance of the longitudinal reinforcement traction device to control the spacing between the steel meshes.

[0033] In the preferred solution, the following steps are further included: S9, separately manufacturing a bottom plate body, two groups of web plate bodies, two groups of hook bar blocks, and two groups of top plate bodies;

[0034] S10, using a mobile formwork, sequentially hoisting the bottom plate body and the two sets of web plates into the outer formwork, and connecting and fixing the bottom plate body and the two sets of web plates;

[0035] S11. Hoist two sets of hook bar blocks and connect and secure them to the bottom plate and web plate respectively;

[0036] S12, hoisting inner mold;

[0037] S13, hoisting two sets of roof panels, fixing the roof panels to the web panels, and fixing the two sets of roof panels to each other;

[0038] The above steps can realize the industrialized intelligent production of cast-in-place box girder steel components.

[0039] In a preferred embodiment, the step of fixing hook bars on each block is also included;

[0040] Common longitudinal reinforcement and / or common hook reinforcement are provided at the connection positions between the blocks. The common longitudinal reinforcement and / or common hook reinforcement are installed as loose reinforcement after the corresponding blocks are assembled.

[0041] An industrialized intelligent production equipment for cast-in-situ box girder steel bar components, including a steel bar block welding system, which is provided with a longitudinal bar slide, a mesh frame, a block welding device, a longitudinal bar traction device and a finished product platform arranged in sequence along the longitudinal direction;

[0042] On both sides of the longitudinal reinforcement slide, from outside to inside, there are reinforcement spreading device, longitudinal reinforcement feeding device and reinforcement dropping telescopic arm;

[0043] Two sets of longitudinal reinforcement slides are provided on the longitudinal reinforcement slide seat, and a plurality of longitudinal reinforcement positioning grooves are provided on the top of the longitudinal reinforcement slides.

[0044] The reinforcement loosening device is used to loosen bundles of longitudinal reinforcement;

[0045] The longitudinal reinforcement feeding device is used to lift a single longitudinal reinforcement and drop it onto a reinforcement dropping telescopic arm, which is located below the longitudinal reinforcement feeding device and above the longitudinal reinforcement slide. The reinforcement dropping telescopic arm is used to drop the longitudinal reinforcement into the corresponding longitudinal reinforcement positioning groove by telescoping. Alternatively, the reinforcement dropping telescopic arm is composed of at least two sets of joint mechanical arms on each side, and the joint mechanical arms are used to clamp the longitudinal reinforcement and place it into the corresponding longitudinal reinforcement positioning groove.

[0046] A slide locking mechanism is provided between the two sets of longitudinal reinforcement slides, which is used to temporarily fix the two sets of longitudinal reinforcement slides and connect them so that the two sets of longitudinal reinforcement slides can slide synchronously to pass the ends of the longitudinal reinforcement through the steel mesh;

[0047] The mesh rack is used to accommodate multiple steel meshes and keep the steel meshes vertical at all times;

[0048] The block welding device is provided with a plurality of movable block welding heads for welding and connecting the steel mesh and the longitudinal reinforcement;

[0049] The longitudinal reinforcement traction device is used to be fixedly connected to the end of the longitudinal reinforcement and to pull the longitudinal reinforcement along the finished platform.

[0050] In the preferred solution, the reinforcement spreading device is composed of a longitudinal reinforcement spreading platform, a reinforcement spreading platform and a reinforcement leveling platform which are arranged in sequence from the inside.

[0051] The longitudinal reinforcement loose-bundling platform is equipped with multiple longitudinal reinforcement loose-bundling top blocks and multiple longitudinal reinforcement loose-bundling tape machines that can be raised and lowered repeatedly. The longitudinal reinforcement loose-bundling platform is used to roughly break up, straighten out and flatten the bundled longitudinal reinforcement.

[0052] There are multiple reinforcement tape machines on the reinforcement separation platform, which are used to further break up the longitudinal reinforcement by controlling the conveying speed of the reinforcement tape machines;

[0053] The reinforcement leveling platform is equipped with multiple repeatedly rising and falling reinforcement leveling blocks and reinforcement leveling tape machines, which are used to further break up and flatten the longitudinal reinforcement.

[0054] The conveying direction of the longitudinal reinforcement loose-bundling belt machine, reinforcement dividing belt machine and reinforcement leveling belt machine is the direction of the longitudinal reinforcement slide.

[0055] In the preferred solution, the longitudinal reinforcement feeding device is provided with multiple movable steps and fixed steps. The movable step is provided with multiple steps from low to high on the side away from the longitudinal reinforcement slide. The side of each step close to the longitudinal reinforcement slide is lower and the other side is higher. The movable step performs reciprocating lifting motion.

[0056] A plurality of steps from low to high are provided on the side of the step platform away from the longitudinal reinforcement sliding seat. The side of each step close to the longitudinal reinforcement sliding seat is lower and the other side is higher. A slope is provided on the top of the step platform. The side of the slope close to the longitudinal reinforcement sliding seat is lower and the other side is higher.

[0057] When the movable step platform is aligned with the fixed step platform during the lifting process, each step of the fixed step platform can only accommodate one longitudinal reinforcement.

[0058] In the preferred solution, there are two groups of telescopic arms for dropping the reinforcement, which are located on both sides above the longitudinal reinforcement slide. The telescopic direction of the telescopic arms for dropping the reinforcement is toward the longitudinal reinforcement slide. The top of the telescopic arms for dropping the reinforcement is provided with an inclined surface, and the end close to the longitudinal reinforcement slide is lower, so that the longitudinal reinforcement dropped on the telescopic arms can roll toward the longitudinal reinforcement slide.

[0059] In a preferred solution, a rib drop sensor is provided at the top end of the rib drop telescopic arm. The rib drop sensor adopts a Hall sensor, a magnetic sensor or a reflective photoelectric sensor to detect whether a longitudinal rib has fallen.

[0060] In a preferred solution, the slide locking mechanism is a set of liftable connecting pins, which are used to temporarily fix and connect the two sets of longitudinal reinforcement slides.

[0061] In a preferred embodiment, the top surface and one end of the mesh frame are open, and the other end is limited to the steel mesh, but there is space for the arranged longitudinal bars to pass through, and the longitudinal bars of the bottom layer pass through the inner side of the upper surface higher than the bottom of the steel mesh;

[0062] Sliding mesh positioning claws are provided on both sides of the mesh frame, and at least one retractable positioning mechanism is provided on the mesh positioning claws for fixing the first steel mesh;

[0063] The mesh frame is also provided with a mesh position acquisition camera for acquiring the position of the steel mesh currently located at the first position, so that the positioning mechanism of the mesh positioning claws can fix the position of the steel mesh currently located at the first position.

[0064] In a preferred embodiment, the block welding device is a multi-joint robotic arm, and a block welding head is provided at the free end of the robotic arm;

[0065] Alternatively, the block welding device is provided with a block welding gantry that can move longitudinally, a plurality of block welding carriages are provided on the block welding gantry, a welding head lifting device is provided on the block welding carriage, and the welding head lifting device is connected to the block welding head.

[0066] In a preferred solution, a block welding point acquisition camera is provided on the block welding gantry or the block welding head.

[0067] In a preferred embodiment, the longitudinal reinforcement traction device is provided with a traction frame that travels in the longitudinal direction, the traction frame is provided with a longitudinal reinforcement fixing device, the traction frame is further provided with a one-way locking device and a traction cylinder, the one-way locking device is connected to the traction guide rail on the finished product platform, one end of the traction cylinder is connected to the one-way locking device, and the other end of the traction cylinder is connected to the traction frame;

[0068] The traction frame is also provided with a longitudinal reinforcement end baffle for aligning the longitudinal reinforcement ends.

[0069] In a preferred embodiment, the longitudinal reinforcement fixing device is provided with a first bite head and a second bite head that are arranged relatively to each other, and the first bite head and the second bite head are arranged to slide relative to each other. A plurality of rubber sleeves for the longitudinal reinforcement to pass through are provided between the first bite head and the second bite head, and bite teeth are provided on opposite sides of the first bite head and the second bite head. The relative sliding between the first bite head and the second bite head causes the rubber sleeve to deform so as to fix the end of the longitudinal reinforcement to the traction frame.

[0070] In the preferred solution, the longitudinal reinforcement fixing device is provided with two sets of movable baffles that can be temporarily fixed. The movable baffles are provided with cavities for the longitudinal reinforcements. A plurality of relatively arranged ratchets are provided in the cavities. The ratchets are used to fix the ends of the longitudinal reinforcements and the traction frame when the longitudinal reinforcements pass through.

[0071] In the preferred embodiment, a plurality of groups of relatively arranged one-way limit claws are provided in the one-way locking device, and the one-way limit claws are connected to the housing of the one-way locking device through a rotating pin. A coil spring is also provided on the rotating pin to make the one-way limit claws tend to support the traction guide rail in a single direction.

[0072] In a preferred solution, a reset rod is further provided, and the reset rod is located between the one-way limiting claw and the traction guide rail to disengage the one-way limiting claw from the traction guide rail.

[0073] The preferred solution also includes a steel mesh forming system, with movable guide rails on both sides, a movable welding gantry on the movable guide rails, a plurality of movable welding trolleys on the movable welding gantry, and a liftable welding head on the movable welding trolley;

[0074] A steel mesh forming platform is provided between the movable guide rails, and a plurality of steel bar positioning clamps are provided on the steel mesh forming platform for fixing the steel bar unit components.

[0075] In a preferred solution, a transport robot arm is further provided, and the transport robot arm is used to move the forming platform.

[0076] The present invention provides an industrial intelligent production method and equipment for cast-in-situ box girder steel bar components, which produces cast-in-situ box girder steel bar components in an industrial intelligent manner. In the industrial production process, high-precision steel bar units and steel bar blocks can be obtained. Through an intelligent system, including sensors and algorithms, the dimensional accuracy of the steel bar units and steel bar blocks can be ensured, thereby ensuring the quality of the steel bar components. The use of a mechanized production method can greatly improve production efficiency and reduce labor intensity. For the construction site, this method can effectively reduce the number of construction workers on site, leaving only a small number of people on site to carry out modular assembly of the box girder forming, which can greatly reduce the safety risks on the construction site. At the same time, since the box girder steel bar structure is all produced in a factory, it can effectively avoid construction windows and safeguard the construction period of the construction company. The present invention reconstructs the process and equipment for the construction of cast-in-situ box girder steel bar components, greatly improving the efficiency and safety of bridge construction. In the process of repeated construction, it can also effectively reduce the overall cost and has great application benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0077] The present invention will be further described below with reference to the accompanying drawings and examples:

[0078] Figure 1 It is a three-dimensional diagram of the steel mesh forming platform of the present invention.

[0079] Figure 2 It is a top view of the steel mesh forming system of the present invention.

[0080] Figure 3 It is a top view of the mesh frame of the present invention.

[0081] Figure 4 It is a front cross-sectional view of the mesh frame of the present invention.

[0082] Figure 5 It is a top view schematic diagram of the steel bar block welding system of the present invention.

[0083] Figure 6 for Figure 5 AA cross-sectional view of .

[0084] Figure 7 for Figure 5 BB cross-sectional diagram.

[0085] Figure 8 for Figure 5 Schematic diagram of CC cross-section.

[0086] Figure 9 for Figure 5CC cross-sectional schematic diagram of another preferred embodiment.

[0087] Figure 10 It is a structural schematic diagram of the one-way locking device of the present invention.

[0088] Figure 11 It is a three-dimensional diagram of the roof plate body of the present invention.

[0089] Figure 12 This is an exploded cross-sectional view of the cast-in-situ box girder reinforcement component of the present invention.

[0090] Figure 13 It is a structural schematic diagram of the present invention using a movable formwork to hoist steel bar blocks.

[0091] Figure 14 It is a schematic cross-sectional view of the connection between the bottom plate body and the web plate body in the cast-in-situ box girder reinforcement component of the present invention.

[0092] Figure 15 It is a schematic cross-sectional view of the cast-in-situ box girder reinforcement component of the present invention after the hook bar block is hoisted.

[0093] Figure 16 It is a schematic cross-sectional view of the cast-in-situ box girder reinforcement component of the present invention after the inner formwork is hoisted.

[0094] Figure 17 It is a schematic cross-sectional view of the cast-in-situ box girder reinforcement components after hoisting is completed according to the present invention.

[0095] In the figure: steel mesh forming platform 1, steel unit element 2, steel positioning fixture 3, mobile welding gantry 4, welding gantry slide 41, mobile welding trolley 42, mobile guide rail 5, handling robot 6, placement rack 7, steel mesh 8, mesh rack 9, mesh rack frame 91, mesh positioning claw 92, mesh first positioning mechanism 93, mesh second positioning mechanism 94, mesh position acquisition camera 95, mesh rack slide 96, block welding device 10, block welding door Frame 101, block welding carriage 102, welding head lifting device 103, block welding head 104, block weld spot acquisition camera 105, finished product platform 11, traction guide rail 111, longitudinal reinforcement slide 12, slide guide rail 121, upper longitudinal reinforcement slide 13, upper longitudinal reinforcement positioning groove 131, slide locking mechanism 132, lower longitudinal reinforcement slide 14, lower longitudinal reinforcement positioning groove 141, longitudinal reinforcement loose bundling platform 15, longitudinal reinforcement loose bundling top block 151, longitudinal reinforcement loose bundling tape machine 1 52, reinforcement platform 16, reinforcement belt machine 161, reinforcement leveling platform 17, reinforcement leveling top block 171, reinforcement leveling belt machine 172, longitudinal reinforcement feeding device 18, moving step platform 181, fixed step platform 182, connecting rod 183, driving device 184, reinforcement drop telescopic arm 19, reinforcement drop sensor 191, longitudinal reinforcement traction device 20, traction frame 201, first bite head 202, rubber sleeve 203, second bite head 204, bite teeth 205, bite drive device 206, single Towards locking device 207, one-way limit claw 2071, rotating pin 2072, coil spring 2073, reset rod 2074, traction cylinder 208, stroke sensor 209, longitudinal reinforcement end baffle 210, movable baffle 211, ratchet 212, longitudinal reinforcement 21, hook reinforcement 22, box girder reinforcement component 1000, bottom plate body 200, web plate body 300, top plate body 400, hook reinforcement block 500, movable formwork 601, outer formwork 602, inner formwork 603. DETAILED DESCRIPTION

[0096] Example 1:

[0097] An industrialized intelligent production method for cast-in-situ box girder steel bar components, comprising the following steps:

[0098] S1, according to the design size to produce steel unit element 2, and assemble into steel mesh 8; Figure 1 As shown in FIG, a bending center or a CNC bending machine is used in a processing plant to bend the steel bar unit 2. The preferred solution is as follows: Figure 2In the figure, the assembly of the steel mesh 8 is completed on the steel mesh forming platform 1, and a plurality of steel bar positioning clamps 3 are provided on the steel mesh forming platform 1, and the steel bar positioning clamps 3 are commercially available products. The steel bar unit elements 2 after bending and shaping are placed on the steel mesh forming platform 1 and fixed by the steel bar positioning clamps 3; a mobile welding device is also provided, and the mobile welding device is provided with an identification device for identifying the positions of the welds between the steel bar units 2 according to the design requirements, and then the mobile welding trolley 42 on the mobile welding device is moved to the weld position, which is usually the position where two steel bars overlap, and the weld position is welded and connected by the welding head. The mobile welding device in this example can adopt an articulated robotic arm structure, or a Cartesian robotic arm structure. In this example, Figure 2 As shown in , a Cartesian robot arm structure is preferably adopted because a plurality of mobile welding carriages 42 can be provided on the welding gantry slide rail 41 to improve processing efficiency.

[0099] S2, vertically arranging multiple steel meshes 8 into the mesh rack 9; placing the steel sheet on a dedicated sheet rack and transporting it to the sheet storage area of ​​the block processing plant by vehicle or ship;

[0100] The preferred solution is Figure 3 、 4 In the embodiment, the top surface and one end of the mesh frame 9 are open, and the other end is limited to the steel mesh 8, but can be used for the arranged longitudinal reinforcement 21 to pass through. The longitudinal reinforcement 21 located at the bottom layer passes through the inner side of the steel mesh 8;

[0101] Sliding mesh positioning claws 92 are provided on both sides of the mesh frame 9. The mesh positioning claws 92 are driven by a synchronous belt structure to move longitudinally along the mesh frame 9. The mesh positioning claws 92 are provided with at least one positioning mechanism for fixing the first steel mesh 8; preferably, the positioning mechanism is a retractable rod for blocking the steel mesh 8.

[0102] The mesh frame 9 is also provided with a mesh position acquisition camera 95 for acquiring the position of the current first steel mesh 8 so that the positioning mechanism can fix the current first steel mesh 8. Figure 4 As shown in the figure, the positioning mechanism is divided into two groups, namely the first mesh positioning mechanism 93 and the second mesh positioning mechanism 94. The reason for setting up two groups is that when the first mesh positioning mechanism 93 loosens the first steel mesh 8, the second mesh positioning mechanism 94 can fix the second steel mesh 8, thereby preventing the second steel mesh 8 from moving with the longitudinal reinforcement 21 when the longitudinal reinforcement 21 is pulled.

[0103] S3. Arrange the longitudinal reinforcement 21 according to the design dimensions;

[0104] The preferred solution is Figure 5 、6 In the process, the bundled longitudinal bars 21 are shaken out and loaded individually in a width-limited single-bar loading manner;

[0105] A two-layer longitudinal reinforcement slide is provided, and longitudinal reinforcement positioning grooves corresponding to the installation positions of the longitudinal reinforcement 21 are provided on the longitudinal reinforcement slide; the envelope of the longitudinal reinforcement slide is consistent with the design requirements, and the positions and spacings of the longitudinal reinforcement positioning grooves are consistent with the design requirements.

[0106] Below the feeding mechanism and above the longitudinal reinforcement carriage, a retractable rib-dropping telescopic arm 19 is provided to drop each longitudinal reinforcement 21 into each longitudinal reinforcement positioning slot by dropping the end thereof; alternatively, two articulated robotic arms are provided to deliver each longitudinal reinforcement 21 into each longitudinal reinforcement positioning slot by lifting the material;

[0107] When one layer of longitudinal reinforcement carriage is fully loaded, switch to another layer of longitudinal reinforcement carriage to continue paving; Figure 5 As shown in , the upper longitudinal reinforcement slide 13 and the lower longitudinal reinforcement slide 14 are located at different heights, corresponding to the structures of the upper and lower longitudinal reinforcements of the steel bar block, respectively. Usually, the lower longitudinal reinforcement slide 14 is laid first, and then the upper longitudinal reinforcement slide 13 is slid above the lower longitudinal reinforcement slide 14, and the upper longitudinal reinforcement slide 13 is laid. After the laying is completed, the upper longitudinal reinforcement slide 13 and the lower longitudinal reinforcement slide 14 are locked into a whole by the slide locking mechanism 132. Preferably, the lower longitudinal reinforcement slide 14 is a driven structure and is not provided with an independent power drive, while the upper longitudinal reinforcement slide 13 is an active structure and is provided with an independent drive device. Preferably, the drive device adopts a chain transmission mechanism. The upper longitudinal reinforcement slide 13 is driven by the chain to move along the guide rails on both sides of the longitudinal reinforcement slide 12. A slide guide rail 121 is set near the middle and lower position of the longitudinal reinforcement slide 12, and the lower longitudinal reinforcement slide 14 slides along the slide guide rail 121. That is, the upper longitudinal rib slide 13 and the lower longitudinal rib slide 14 each have their own guide rails.

[0108] Through the above method, the longitudinal reinforcement 21 is arranged according to the design size.

[0109] S4, inserting the longitudinal reinforcement 21 into the plurality of steel meshes 8 along the longitudinal direction;

[0110] In the preferred solution, the two layers of longitudinal reinforcement carriages are moved simultaneously, so that the ends of the longitudinal reinforcement 21 pass through the mesh frame 9 and the steel mesh 8 and are connected to the longitudinal reinforcement traction device 20, and the longitudinal reinforcement traction device 20 pulls the longitudinal reinforcement 21 to move. Figure 5 .

[0111] S5, connecting the longitudinal reinforcement 21 to the first steel mesh 8;

[0112] The preferred solution is Figure 5In the embodiment, a block welding device 10 is provided between the longitudinal reinforcement pulling device 20 and the mesh frame 9 , and the block welding device 10 is used to weld and connect the longitudinal reinforcement 21 to the steel mesh 8 .

[0113] In a preferred solution, an identification device is provided on the block welding device 10 for identifying the positions of the welding points between the steel bar units 2 according to design requirements.

[0114] In a preferred solution, the recognition device uses a dual-camera visual positioning recognition method with a specific spacing. The captured dual-camera images are binarized, and the intersection position within the current field of view is marked. The intersection coordinates are calculated using the visual difference of the dual-camera images combined with trigonometric functions. The intersection coordinates are compared with the designed coordinates. If the error value is within the preset range, welding is performed at the intersection position. If the error value exceeds the preset range, the current weld point is skipped and the next weld point is processed, and an alarm is issued. Further manual processing is required.

[0115] In another optional solution, the recognition device adopts a single-camera visual positioning recognition method, the block welding head 104 of the block welding device 10 is driven by a Cartesian coordinate mechanism, the block welding device 10 moves longitudinally, the recognition device feeds back the image of the steel mesh 8 so that the block welding head 104 is aligned with the steel mesh 8 located at the first position, the block welding carriage 102 of the block welding device 10 moves transversely, the recognition device feeds back the image of the current longitudinal reinforcement 21 so that the block welding head 104 is aligned with the current longitudinal reinforcement 21, and the block welding head 104 welds the first layer of longitudinal reinforcement 21 to the steel mesh 8;

[0116] According to the design size, the block welding head 104 is controlled to fall a certain distance, and the block welding head 104 welds the longitudinal reinforcement 21 of the second layer to the steel mesh 8;

[0117] Preferably, an infrared sensor is provided in the recognition device, and the recognition device uses an artificial intelligence algorithm, such as a CNN algorithm, to detect whether there is a red hot spot of welding in the image, and whether the red hot spot is located at the intersection between the longitudinal reinforcement 21 and the steel mesh 8, and feedback the welding quality.

[0118] S6, the longitudinal reinforcement 21 continues to move for a distance, the distance of which is the same as the distance between the steel meshes 8;

[0119] The preferred solution is Figure 5 、 9 In the embodiment, the longitudinal reinforcement traction device 20 moves along the traction guide rail 111. The longitudinal reinforcement traction device 20 is pulled by a one-way locking device 207 and a traction cylinder 208. The one-way locking device 207 is used to lock the longitudinal reinforcement traction device 20 on the traction guide rail 111 in one direction. The traction cylinder 208 is a hydraulic cylinder or a pneumatic cylinder, which is used to pull the entire longitudinal reinforcement traction device 20 and the longitudinal reinforcement 21 to move.

[0120] A stroke sensor 209 is also provided on the longitudinal reinforcement traction device 20, which is used to detect the travel distance of the longitudinal reinforcement traction device 20 to control the spacing between the steel meshes 8. Preferably, the stroke sensor 209 is arranged on one side of the traction guide rail 111. The stroke sensor 209 is a Hall sensor, and correspondingly, different height textures are provided at corresponding positions of the traction guide rail 111, and the traction travel stroke is judged by the changes in the eddy currents generated by these textures. Or the stroke sensor 209 is a magnetic sensor, such as a giant magnetoresistive sensor, and correspondingly, the traction guide rail 111 is made of steel, and different height textures are provided at corresponding positions of the traction guide rail 111. The changes in the magnetic field caused by these textures are used to judge the traction travel stroke. Or the stroke sensor 209 is a reflective photoelectric sensor, and different height textures are provided on the traction guide rail 111, and the traction travel stroke is judged by the changes in the brightness of the reflected light.

[0121] S7, connecting the longitudinal reinforcement 21 to the second steel mesh 8;

[0122] S8, repeat steps S6 to S7 until all the steel meshes 8 are connected to the longitudinal bars 21;

[0123] The above steps enable the industrialized production of steel bar blocks in steel bar components.

[0124] In the block storage factory, the steel blocks are processed into steel blocks to be assembled by arranging hook bars, prestressed pipes and pads;

[0125] The preferred solution is Figure 12 The method further includes the following steps: S9, respectively manufacturing a bottom plate body 200, two groups of web plate bodies 300, two groups of hook bar blocks 500 and two groups of top plate bodies 400;

[0126] S10, such as Figure 13 、 14 In the process, the bottom plate body 200 and the two sets of web plates 300 are sequentially hoisted into the outer mold 602 by the movable mold frame 601, and the bottom plate body 200 and the two sets of web plates 300 are connected and fixed;

[0127] S11, such as Figure 15 In the process, two sets of hook bar blocks 500 are hoisted and connected and fixed to the bottom plate body 200 and the web plate body 300 respectively;

[0128] S12, such as Figure 16 In the middle, the inner mold 603 is hoisted;

[0129] S13, such as Figure 17 In the process, two sets of top plate bodies 400 are hoisted, the top plate bodies 400 are fixedly connected to the web plate bodies 300, and the two sets of top plate bodies 400 are fixedly connected to each other;

[0130] The above steps can realize the industrialized intelligent production of cast-in-place box girder steel components.

[0131] In the preferred solution, the step of fixing hook bars 22 on each block is also included;

[0132] Common longitudinal bars 600 and / or common hook bars 700 are installed at the connections between the blocks. After the blocks are assembled, these bars are installed as loose reinforcement. This prevents interference between the common longitudinal bars 600 and common hook bars 700 during installation.

[0133] In a preferred solution, after the steel bar blocks are fabricated, a camera is placed at a preset location to capture images from the axial direction of the longitudinal bars 21, detecting their positions. These positions are then compared with the designed positions, and any non-compliant longitudinal bars 21 are adjusted and corrected. This detection ensures that the longitudinal bars of the box girder reinforcement components in each bin are aligned, facilitating one-to-one connection.

[0134] Before detecting the position of the longitudinal reinforcement 21, a steel bar block corresponding to the first bin is manufactured according to the designed dimensions. A fixed camera captures an image of the steel bar block in the first bin. The position of the longitudinal reinforcement 21 is identified through artificial intelligence and converted into a coordinate array. The coordinate array of the longitudinal reinforcement 21 position is then stored.

[0135] The specific identification steps are to set a high-brightness light source around the camera, such as a high-brightness LED light source or a hernia light source, and use the high-brightness light source to illuminate the end face of the longitudinal reinforcement 21. Perform regional brightness filtering on the captured image, that is, select pixels with brightness within a range, and then perform contour tracking on the selected area after selection, that is, perform vector ellipse fitting on the selected contour, and filter the vector fitting pattern into a circle or ellipse according to the image of the steel bar block in the first bin, retaining the vector pattern that conforms to the end face of the longitudinal reinforcement 21, and using the midpoint of the vector pattern as the coordinate array of each longitudinal reinforcement 21. Since the camera 8 uses a fixed-position fixed-focus lens, the image obtained by the camera 8 is repeatable. It can well assist in adjusting the position of the longitudinal reinforcement 21 to facilitate the precise docking of the longitudinal reinforcement 21 between the bins, such as group welding docking or threaded sleeve docking, to ensure construction quality.

[0136] When photographing the steel bar components in the subsequent bins, ensure that the axial position of the end of the longitudinal bar 21 is the same as the axial position of the end of the longitudinal bar 21 in the first bin; to avoid errors caused by perspective distortion of the image.

[0137] Capture an image of the steel bar component in the subsequent bin, identify the position of the longitudinal bar 21 through artificial intelligence, convert it into a coordinate array, and compare it with the coordinate array of the position of the longitudinal bar 21 in the steel bar component in the first bin;

[0138] The longitudinal reinforcement 21 whose position error exceeds the preset value range is corrected; while the longitudinal reinforcement 21 whose error is within the preset value range does not need to be corrected.

[0139] In the preferred solution, after the box girder steel bar components are assembled, the end of the box girder steel bar components is imaged again to identify the position of the longitudinal reinforcement 21, and the position of the longitudinal reinforcement 21 is compared with the position of the longitudinal reinforcement 21 of the box girder steel bar components in the first bin. The position of the longitudinal reinforcement 21 that does not meet the requirements is adjusted and corrected. Since adjustments have been made during the production of the steel bar blocks, a simple algorithm can be used in this step, that is, the end face coordinates of 2 to 3 longitudinal reinforcements 21 in a steel bar block are used as the basis for comparison, thereby greatly simplifying the algorithm. If there is a problem where the error exceeds the preset value, it is only necessary to adjust the position between the steel bar blocks, thereby saving a lot of work on adjusting and correcting the longitudinal reinforcement ends. After subsequent hoisting, the adjustment work in the casting bin is also very little. The above steps achieve precise control of the position of the longitudinal reinforcement of the box girder steel bar components. After measurement, through image detection based on artificial intelligence and correction operations on the longitudinal reinforcement 21, the workload of workers in adjusting the steel bars in the casting bin is greatly reduced, the labor intensity is reduced, and the installation efficiency of the steel bar components is improved.

[0140] Example 2:

[0141] like Figure 5 In the invention, an industrial intelligent production equipment for cast-in-situ box girder steel bar components includes a steel bar block welding system, which is provided with a longitudinal bar slide 12, a mesh frame 9, a block welding device 10, a longitudinal bar pulling device 20 and a finished product platform 11 arranged in sequence along the longitudinal direction;

[0142] like Figure 5 In the middle, the two sides of the longitudinal reinforcement slide 12 are provided with a reinforcement dispersing device, a longitudinal reinforcement feeding device 18 and a reinforcement dropping telescopic arm 19 in sequence from the outside to the inside;

[0143] Two sets of longitudinal reinforcement slides are provided on the longitudinal reinforcement slide 12, namely an upper longitudinal reinforcement slide 13 and a lower longitudinal reinforcement slide 14, and a plurality of upper longitudinal reinforcement positioning grooves 131 and a lower longitudinal reinforcement positioning groove 141 are provided on the top of the longitudinal reinforcement slides.

[0144] The tendon loosening device is used to loosen the bundled longitudinal tendons 21;

[0145] The longitudinal reinforcement loading device 18 is used to lift a single longitudinal reinforcement 21 and drop it onto the reinforcement dropping telescopic arm 19, which is located below the longitudinal reinforcement loading device 18 and above the longitudinal reinforcement slide 12; the reinforcement dropping telescopic arm 19 is used to drop the longitudinal reinforcement 21 into the corresponding longitudinal reinforcement positioning groove by telescoping; alternatively, the reinforcement dropping telescopic arm 19 is composed of at least two sets of joint mechanical arms on each side, and the two joint mechanical arms are used to clamp the single longitudinal reinforcement 21 and place it into the corresponding longitudinal reinforcement positioning groove;

[0146] A carriage locking mechanism 132 is provided between the two sets of longitudinal reinforcement carriages. The carriage locking mechanism 132 is a retractable fixed pin driven by a pneumatic cylinder or electric push rod. It is used to temporarily secure the two sets of longitudinal reinforcement carriages together, allowing them to slide synchronously and pass the ends of the longitudinal reinforcement 21 through the steel mesh 8.

[0147] The mesh frame 9 is used to accommodate multiple steel meshes 8 and keep the steel meshes 8 vertical at all times;

[0148] The block welding device 10 is provided with a plurality of movable block welding heads 104 for welding the steel mesh 8 and the longitudinal bars 21;

[0149] The longitudinal reinforcement traction device 20 is used to be fixedly connected to the end of the longitudinal reinforcement 21 and to pull the longitudinal reinforcement 21 to move along the finished product platform 11. With this structure, the production of steel bar blocks can be automated, mechanized and intelligent, thereby improving production accuracy and greatly improving production efficiency.

[0150] The preferred solution is Figure 5 、 6 In the middle, the reinforcement spreading device is composed of a longitudinal reinforcement spreading platform 15, a reinforcement spreading platform 16 and a reinforcement leveling platform 17 which are arranged in sequence from the inside;

[0151] The longitudinal reinforcement unbundling platform 15 is provided with a plurality of longitudinal reinforcement unbundling top blocks 151 that are repeatedly raised and lowered, and a plurality of longitudinal reinforcement unbundling tape machines 152. The longitudinal reinforcement unbundling top blocks 151 are driven to rise and fall back and forth by a cylinder or a cam mechanism. The longitudinal reinforcement unbundling platform 15 is used to roughly break up, straighten out and flatten the bundled longitudinal reinforcements 21; the longitudinal reinforcement unbundling tape machines 152 roughly flatten the longitudinal reinforcements by conveying.

[0152] A plurality of reinforcement-splitting tape machines 161 are provided on the reinforcement-splitting platform 16, which are used to further break up the longitudinal reinforcement 21 by controlling the conveying speed of the reinforcement-splitting tape machine 161; by controlling the speed of the reinforcement-splitting tape machine 161, for example, making the conveying speed of the reinforcement-splitting tape machine 161 lower than the longitudinal reinforcement-loosening tape machine 152, and adopting a three-step forward and two-step backward method, the longitudinal reinforcement is further broken up by reciprocating swinging.

[0153] The reinforcement leveling platform 17 is provided with a plurality of repeatedly rising and falling reinforcement leveling blocks 171 and reinforcement leveling tape machines 172. The reinforcement leveling platform 17 is used to further break up and flatten the longitudinal reinforcements 21. The reinforcement leveling blocks 171 are driven to rise and fall back and forth by a cylinder or a cam mechanism to further flatten the longitudinal reinforcements 21.

[0154] The conveying directions of the longitudinal reinforcement bulking tape machine 152 , the reinforcement dividing tape machine 161 and the reinforcement leveling tape machine 172 are all in the direction of the longitudinal reinforcement slide 12 .

[0155] The preferred solution is Figure 6The longitudinal bar feeding device 18 is equipped with multiple movable platforms 181 and fixed platforms 182. The movable platform 181 is driven by a cylinder, cam mechanism, or crank mechanism to achieve reciprocating movement. The side of the movable platform 181 away from the longitudinal bar slide 12 is equipped with multiple steps from low to high. Each step is lower on the side closest to the longitudinal bar slide 12 and higher on the other side. This allows the rebar to roll to the lower position, allowing the movable platform 181 to perform reciprocating movement.

[0156] The side of the step platform 182 away from the longitudinal reinforcement slide 12 is provided with multiple steps from low to high, and the side of each step close to the longitudinal reinforcement slide 12 is lower and the other side is higher. The top of the step platform 182 is provided with a slope, and the side of the slope close to the longitudinal reinforcement slide 12 is lower and the other side is higher;

[0157] When the movable step platform 181 is aligned with the fixed step platform 182 during the lifting process, only one longitudinal reinforcement 21 can be accommodated on each step of the fixed step platform 182. Figure 6 As shown in . With this structure, each time the movable step platform 181 is lifted, even if one longitudinal reinforcement 21 lifts the step of a fixed step platform 182, until the top of the fixed step platform 182 is reached.

[0158] The preferred solution is Figure 5 、 6 In the figure, there are two groups of rebar-dropping telescopic arms 19, which are located on both sides above the longitudinal rebar slide 12. The telescopic direction of the rebar-dropping telescopic arms 19 is toward the longitudinal rebar slide 12. The top of the rebar-dropping telescopic arm 19 is provided with an inclined surface, and the end close to the longitudinal rebar slide 12 is lower, so that the longitudinal rebar 21 dropped on the rebar-dropping telescopic arm 19 can roll toward the longitudinal rebar slide.

[0159] The preferred solution is Figure 6 In the embodiment, a rib dropping sensor 191 is provided at the top end of the rib dropping telescopic arm 19. The rib dropping sensor 191 adopts a Hall sensor, a magnetic sensor or a reflective photoelectric sensor to detect whether a longitudinal rib 21 has fallen and the number of the fallen ribs.

[0160] In another optional solution, the reinforcement telescopic arm 19 can also be a joint mechanical arm, which grabs a single longitudinal reinforcement 21 and puts it into the corresponding longitudinal reinforcement positioning groove. As a matching structure, a step for storing the longitudinal reinforcement 21 is provided below the fixed step platform 182.

[0161] The preferred solution is Figure 5 In the embodiment, the carriage locking mechanism 132 is a set of lifting connecting pins for temporarily fixing and connecting the two sets of longitudinal reinforcement carriages. The connecting pins are driven to rise and fall by a cylinder, a cam mechanism or an electric push rod.

[0162] The preferred solution is Figure 3 、 4In the embodiment, the top surface and one end of the mesh frame 9 are open, and the other end is limited to the steel mesh 8, but there is a space for the arranged longitudinal reinforcement 21 to pass through. The longitudinal reinforcement 21 of the bottom layer passes through the inner side of the upper surface higher than the bottom of the steel mesh 8;

[0163] Sliding mesh positioning claws 92 are provided on both sides of the mesh frame 9. The mesh positioning claws 92 are provided with at least one retractable positioning mechanism, which in this example adopts a rod-shaped structure and is driven to retract by a cylinder or an electric push rod to fix the first steel mesh 8;

[0164] The preferred solution is Figure 3 、 4 In this example, the first mesh positioning mechanism 93 and the second mesh positioning mechanism 94 are arranged in sequence. The first mesh positioning mechanism 93 and the second mesh positioning mechanism 94 respectively position the first and second steel meshes 8. When the first steel mesh 8 is connected to the longitudinal reinforcement 21, pulling the longitudinal reinforcement 21 to move will drive the first steel mesh 8 to move with it. At this time, the first mesh positioning mechanism 93 is lifted, and the second mesh positioning mechanism 94 fixes the second steel mesh 8 to prevent the second steel mesh 8 from moving with the longitudinal reinforcement 21. When the longitudinal reinforcement 21 stops moving, the mesh positioning claw 92 is moved back to the position of one steel mesh.

[0165] The mesh frame 9 is also provided with a mesh position acquisition camera 95 for acquiring the position of the first steel mesh 8 currently located, so that the positioning mechanism of the mesh positioning claw 92 can fix the position of the first steel mesh 8 currently located.

[0166] In a preferred embodiment, the block welding device 10 is a multi-joint robotic arm, and a block welding head 104 is provided at the free end of the robotic arm;

[0167] Another option is Figure 7 In the embodiment, the block welding device 10 is equipped with a longitudinally movable block welding gantry 101. Multiple block welding carriages 102 are mounted on the block welding gantry 101. A welding head lifting device 103 is mounted on the block welding carriages 102. The welding head lifting device 103 is connected to a block welding head 104. This structure enables multiple block welding heads 104 to operate simultaneously, improving efficiency. This solution is particularly suitable for welding array welds.

[0168] In a preferred solution, a block welding point acquisition camera 105 is provided on the block welding gantry 101 or the block welding head 104 .

[0169] The preferred solution is Figure 5 、 10In the embodiment, the longitudinal reinforcement traction device 20 is provided with a traction frame 201 that travels in the longitudinal direction, the traction frame 201 is provided with a longitudinal reinforcement fixing device, the traction frame 201 is also provided with a one-way locking device 207 and a traction cylinder 208, the one-way locking device 207 is connected to the traction guide rail 111 on the finished product platform 11, one end of the traction cylinder 208 is connected to the one-way locking device 207, and the other end of the traction cylinder 208 is connected to the traction frame 201; the preferred solution is as follows Figure 10 In the one-way locking device 207, a plurality of mutually opposed one-way limiting claws 2071 are provided. The one-way limiting claws 2071 are connected to the housing of the one-way locking device 207 via a rotating pin 2072. A coil spring 2073 is also provided on the rotating pin 2072 to force the one-way limiting claws 2071 to press against the traction guide rail 111 in a single direction. The traction cylinder 208 is a hydraulic cylinder. When the piston rod of the traction cylinder 208 is extended, the one-way limiting claws 2071 of the one-way locking device 207 disengage from the traction guide rail 111 and travel a certain distance. When the piston rod of the traction cylinder 208 is retracted, the one-way limiting claws 2071 are locked to the traction guide rail 111, the traction frame 201 is dragged a certain distance, and the corresponding longitudinal reinforcement 21 travels a certain distance.

[0170] The preferred solution is Figure 10 In the embodiment, a reset rod 2074 is further provided, and the reset rod 2074 is located between the one-way limiting claw 2071 and the pulling guide rail 111 to disengage the one-way limiting claw 2071 from the pulling guide rail 111.

[0171] The traction frame 201 is also provided with a longitudinal reinforcement end baffle 210 for aligning the ends of the longitudinal reinforcement 21. When the upper longitudinal reinforcement slide 13 and the lower longitudinal reinforcement slide 14 are conveying the longitudinal reinforcement 21, the ends of the longitudinal reinforcement 21 directly resist the longitudinal reinforcement end baffle 210 so that the ends of each longitudinal reinforcement 21 are aligned with each other.

[0172] The preferred solution is Figure 8 As shown in the figure, the longitudinal reinforcement fixing device is provided with a first bite head 202 and a second bite head 204 arranged relatively to each other, and the first bite head 202 and the second bite head 204 are arranged to slide relative to each other, and a plurality of rubber sleeves 203 for the longitudinal reinforcement 21 to pass through are provided between the first bite head 202 and the second bite head 204, and bite teeth 205 are provided on the opposite sides of the first bite head 202 and the second bite head 204. The first bite head 202 and the second bite head 204 are driven by a bite drive device 206, preferably a cylinder, to make the first bite head 202 and the second bite head 204 slide relative to each other, and the bite teeth 205 deform the rubber sleeve 203 to bite the longitudinal reinforcement 21, so that the end of the longitudinal reinforcement 21 is fixed to the traction frame 201.

[0173] The preferred solution is Figure 9In the embodiment, the longitudinal reinforcement fixing device is provided with two sets of movable baffles 211 for temporary fixation. Preferably, the movable baffles 211 are connected to the traction frame 201 using magnets. The connection position is located on the side of the traction frame 201 away from the longitudinal reinforcement 21, and the traction frame 201 prevents the movable baffles 211 from axial displacement. The movable baffles 211 are provided with a cavity for the longitudinal reinforcement 21. A plurality of relatively arranged ratchet teeth 212 are provided in the cavity. The ratchet teeth 212 are used to engage the ends of the longitudinal reinforcement 21 when the longitudinal reinforcement 21 passes through, thereby fixing the ends of the longitudinal reinforcement 21 to the traction frame 201.

[0174] The preferred solution is Figure 1 、 2 The invention also includes a steel mesh forming system, wherein movable guide rails 5 are provided on both sides, a movable welding gantry 4 is provided on the movable guide rails 5, a plurality of movable welding carriages 42 are provided on the movable welding carriages 42, and a liftable welding head is provided on the movable welding carriages 42;

[0175] A steel mesh forming platform 1 is provided between the movable guide rails 5 , and a plurality of steel bar positioning fixtures 3 are provided on the steel mesh forming platform 1 for fixing the steel bar unit elements 2 .

[0176] The preferred solution is Figure 2 In the figure, a transport robot arm 6 is further provided, which is used to move the forming platform 1.

[0177] The above embodiments are merely preferred technical solutions of the present invention and should not be construed as limiting the present invention. The embodiments and features in the embodiments of this application may be arbitrarily combined with each other unless they conflict. The scope of protection of the present invention shall be the technical solutions described in the claims, including equivalent alternatives to the technical features of the technical solutions described in the claims. Equivalent alternatives and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. An industrial intelligent production method for cast-in-situ box girder steel bar components, characterized by The following steps are involved: S1, manufacturing steel bar unit elements (2) according to design dimensions and assembling them into steel mesh (8); S2, vertically arranging a plurality of steel mesh sheets (8) and placing them into a mesh frame (9); The top surface and one end of the mesh frame (9) are open, and the other end is limited to the steel mesh (8), but can allow the arranged longitudinal reinforcement (21) to pass through. The longitudinal reinforcement (21) located at the bottom layer passes through the inner side of the steel mesh (8); Sliding mesh positioning claws (92) are provided on both sides of the mesh frame (9), and at least one positioning mechanism is provided on the mesh positioning claws (92) for fixing the first steel mesh (8); S3, arrange the longitudinal reinforcement (21) according to the design size; Two layers of longitudinal reinforcement slides are provided, and longitudinal reinforcement positioning grooves corresponding to the installation positions of the longitudinal reinforcements (21) are provided on the longitudinal reinforcement slides; S4, inserting the longitudinal reinforcement (21) into the plurality of steel meshes (8) along the longitudinal direction; The two layers of longitudinal reinforcement slides are moved simultaneously, so that the ends of the longitudinal reinforcements (21) pass through the mesh frame (9) and the steel mesh (8) and are connected to the longitudinal reinforcement traction device (20), and the longitudinal reinforcement traction device (20) tractions the longitudinal reinforcements (21) to move; S5, connecting the longitudinal reinforcement (21) to the first steel mesh (8); A block welding device (10) is provided between the longitudinal reinforcement pulling device (20) and the mesh frame (9), and the block welding device (10) is used to weld the longitudinal reinforcement (21) to the steel mesh (8); S6, the longitudinal reinforcement (21) continues to move for a distance, the distance being the same as the spacing between the steel meshes (8); The longitudinal reinforcement traction device (20) moves along the traction guide rail (111). The longitudinal reinforcement traction device (20) is tractioned by a one-way locking device (207) and a traction cylinder (208). The one-way locking device (207) is used to lock the longitudinal reinforcement traction device (20) on the traction guide rail (111) in one direction. The traction cylinder (208) is a hydraulic cylinder or a pneumatic cylinder and is used to drag the entire longitudinal reinforcement traction device (20) and the longitudinal reinforcement (21) to move. S7, connecting the longitudinal reinforcement (21) to the second steel mesh (8); S8, repeating steps S6 to S7 until all the steel meshes (8) are connected to the longitudinal bars (21); The above steps enable the industrialized production of steel bar blocks in steel bar components.

2. The industrialized intelligent production method for cast-in-situ box girder steel bar components according to claim 1 is characterized by: In step S1, the steel mesh (8) is assembled on a steel mesh forming platform (1), a plurality of steel bar positioning fixtures (3) are provided on the steel mesh forming platform (1), and the shaped steel bar unit elements (2) are placed on the steel mesh forming platform (1) and fixed by the steel bar positioning fixtures (3); A mobile welding device is also provided, and the mobile welding device is provided with an identification device for identifying the positions of welding points between the steel bar units (2) according to design requirements.

3. The industrialized intelligent production method for cast-in-situ box girder steel bar components according to claim 1 is characterized by: In step S2, A mesh position acquisition camera (95) is also provided on the mesh frame (9) for acquiring the position of the steel mesh (8) currently located first, so that the positioning mechanism can fix the steel mesh (8) currently located first.

4. The method for industrialized intelligent production of cast-in-situ box girder steel bar components according to claim 1 is characterized by: In step S3, the bundled longitudinal bars (21) are shaken out and loaded individually in a width-limited single-bar loading manner; Below the feeding mechanism and above the longitudinal reinforcement carriage, a retractable rib-dropping telescopic arm (19) is provided to drop each longitudinal reinforcement (21) into each longitudinal reinforcement positioning groove in a manner of dropping the end thereof; or, two joint mechanical arms are provided to deliver each longitudinal reinforcement (21) into each longitudinal reinforcement positioning groove in a manner of lifting the material; After one layer of longitudinal reinforcement carriage is fully loaded, switch to another layer of longitudinal reinforcement carriage to continue paving; By the above method, the longitudinal reinforcement (21) is arranged according to the design size.

5. The industrialized intelligent production method of cast-in-situ box beam steel bar components according to claim 1 is characterized in that: The block welding device (10) is provided with an identification device for identifying the positions of welding points between the steel bar unit elements (2) according to design requirements.

6. The industrialized intelligent production method for cast-in-situ box girder steel bar components according to claim 2 or 5, characterized in that: The recognition device adopts a dual-camera visual positioning recognition method with a specific spacing. The collected dual-camera images are binarized separately, the intersection position within the current field of view working range is marked, and the intersection position coordinates are calculated using the visual difference of the dual-camera images combined with trigonometric functions. The intersection position coordinates are compared with the design coordinates. When the error value is within the preset range, welding is performed at the intersection position. If the error value exceeds the preset range, the current welding point is skipped, the next welding point is processed, and an alarm is issued.

7. The method for industrialized intelligent production of cast-in-situ box girder steel bar components according to claim 5 is characterized by: The recognition device adopts a single-camera visual positioning recognition method, the block welding head (104) of the block welding device (10) is driven by a Cartesian coordinate mechanism, the block welding device (10) moves longitudinally, the recognition device feeds back an image of the steel mesh (8) so that the block welding head (104) is aligned with the steel mesh (8) located at the first position, the block welding carriage (102) of the block welding device (10) moves transversely, the recognition device feeds back an image of the current longitudinal reinforcement (21) so that the block welding head (104) is aligned with the current longitudinal reinforcement (21), and the block welding head (104) welds the first layer of longitudinal reinforcement (21) to the steel mesh (8); According to the design size, the block welding head (104) is controlled to fall a certain distance, and the block welding head (104) welds the longitudinal reinforcement (21) of the second layer to the steel mesh (8); The recognition device detects whether there is a red hot spot of welding in the image, and whether the red hot spot is located at the intersection between the longitudinal reinforcement (21) and the reinforcement mesh (8), and provides feedback on the welding quality.

8. The industrialized intelligent production method of cast-in-situ box beam steel bar components according to claim 1 is characterized in that: The longitudinal reinforcement traction device (20) is also provided with a travel sensor (209) for detecting the travel distance of the longitudinal reinforcement traction device (20) to control the spacing between the reinforcement meshes (8).

9. The industrialized intelligent production method for cast-in-situ box beam steel bar components according to claim 1 is characterized in that The following steps are involved: S9, respectively manufacturing a bottom plate body (200), two groups of web plate bodies (300), two groups of hook reinforcement blocks (500) and two groups of top plate bodies (400); S10, using the movable formwork (601), sequentially hoisting the bottom plate body (200) and the two sets of web plate bodies (300) into the outer formwork (602), and connecting and fixing the bottom plate body (200) and the two sets of web plate bodies (300); S11, hoisting two sets of hook bar blocks (500), and connecting and fixing them to the bottom plate body (200) and the web plate body (300) respectively; S12, hoisting inner mold (603); S13, hoisting two sets of top plate bodies (400), fixing the top plate bodies (400) and the web plate bodies (300), and fixing the two sets of top plate bodies (400) to each other; The above steps can realize the industrialized intelligent production of cast-in-place box girder steel components.

10. The industrialized intelligent production method for cast-in-situ box girder steel bar components according to claim 9, characterized in that: The step also includes fixing hook bars (22) on each block; Common longitudinal reinforcement (600) and / or common hook reinforcement (700) are provided at the connection positions between the blocks. The common longitudinal reinforcement (600) and / or common hook reinforcement (700) are installed as loose reinforcement after the corresponding blocks are assembled.

11. An industrialized intelligent production equipment for cast-in-situ box girder steel bar components, characterized by: The invention comprises a steel bar block welding system, wherein the steel bar block welding system is provided with a longitudinal bar slide seat (12), a mesh frame (9), a block welding device (10), a longitudinal bar pulling device (20) and a finished product platform (11) arranged in sequence along the longitudinal direction; On both sides of the longitudinal reinforcement slide (12), from outside to inside, there are provided a reinforcement dispersing device, a longitudinal reinforcement feeding device (18), and a reinforcement dropping telescopic arm (19); Two groups of longitudinal reinforcement slides are provided on the longitudinal reinforcement slide seat (12) and slide along the longitudinal direction, and a plurality of longitudinal reinforcement positioning grooves are provided on the top of the longitudinal reinforcement slide; The tendon loosening device is used to loosen bundled longitudinal tendons (21); The longitudinal reinforcement feeding device (18) is used to lift a single longitudinal reinforcement (21) and drop it onto a reinforcement dropping telescopic arm (19), which is located below the longitudinal reinforcement feeding device (18) and above the longitudinal reinforcement slide (12); the reinforcement dropping telescopic arm (19) is used to make the longitudinal reinforcement (21) drop into the corresponding longitudinal reinforcement positioning groove by telescoping; or, the reinforcement dropping telescopic arm (19) is composed of at least two sets of joint mechanical arms on each side, and the joint mechanical arms are used to clamp the longitudinal reinforcement (21) and place it into the corresponding longitudinal reinforcement positioning groove; A slide locking mechanism (132) is provided between the two sets of longitudinal reinforcement slides for temporarily fixing the two sets of longitudinal reinforcement slides so that the two sets of longitudinal reinforcement slides slide synchronously to pass the ends of the longitudinal reinforcements (21) through the steel mesh (8); The mesh frame (9) is used to accommodate a plurality of steel meshes (8) and to keep the steel meshes (8) always vertical; The top surface and one end of the mesh frame (9) are open, and the other end is limited to the steel mesh (8), but is provided with a space for the arranged longitudinal reinforcement (21) to pass through, and the longitudinal reinforcement (21) of the bottom layer passes through the inner side of the upper surface higher than the bottom of the steel mesh (8); Sliding mesh positioning claws (92) are provided on both sides of the mesh frame (9), and at least one retractable positioning mechanism is provided on the mesh positioning claws (92) for fixing the first steel mesh (8); a plurality of movable block welding heads (104) are provided on the block welding device (10) for welding the steel mesh (8) and the longitudinal reinforcement (21) together; The longitudinal reinforcement traction device (20) is used to be fixedly connected to the end of the longitudinal reinforcement (21) and to pull the longitudinal reinforcement (21) to move along the finished product platform (11); The longitudinal reinforcement traction device (20) is provided with a traction frame (201) that moves in the longitudinal direction, the traction frame (201) is provided with a longitudinal reinforcement fixing device, the traction frame (201) is also provided with a one-way locking device (207) and a traction cylinder (208), the one-way locking device (207) is connected to the traction guide rail (111) on the finished product platform (11), one end of the traction cylinder (208) is connected to the one-way locking device (207), and the other end of the traction cylinder (208) is connected to the traction frame (201); The traction frame (201) is also provided with a longitudinal reinforcement end baffle (210) for aligning the ends of the longitudinal reinforcement (21).

12. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: The reinforcement spreading device comprises a longitudinal reinforcement spreading platform (15), a reinforcement spreading platform (16) and a reinforcement leveling platform (17) which are arranged in sequence from the inside to the outside; The longitudinal reinforcement unbundling platform (15) is provided with a plurality of longitudinal reinforcement unbundling top blocks (151) that are repeatedly raised and lowered and a plurality of longitudinal reinforcement unbundling tape machines (152). The longitudinal reinforcement unbundling platform (15) is used to roughly break up, straighten out and flatten the bundled longitudinal reinforcements (21); A plurality of reinforcement tape machines (161) are provided on the reinforcement-splitting platform (16), and are used to further break up the longitudinal reinforcement (21) by controlling the conveying speed of the reinforcement tape machines (161); A plurality of repeatedly raised and lowered reinforcement top blocks (171) and reinforcement tape machines (172) are provided on the reinforcement leveling platform (17), and the reinforcement leveling platform (17) is used to further break up and flatten the longitudinal reinforcement (21); The conveying directions of the longitudinal reinforcement loose-bundling tape machine (152), the reinforcement dividing tape machine (161) and the reinforcement leveling tape machine (172) are all in the direction of the longitudinal reinforcement slide (12).

13. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11 is characterized by: The longitudinal reinforcement feeding device (18) is provided with a plurality of movable step platforms (181) and fixed step platforms (182). The movable step platform (181) is provided with a plurality of steps from low to high on a side away from the longitudinal reinforcement slide seat (12). The side of each step close to the longitudinal reinforcement slide seat (12) is lower and the other side is higher. The movable step platform (181) performs reciprocating lifting motion. A plurality of steps from low to high are provided on the side of the fixed step platform (182) away from the longitudinal reinforcement slide seat (12), wherein the side of each step close to the longitudinal reinforcement slide seat (12) is lower and the other side is higher, and a slope is provided on the top of the fixed step platform (182), wherein the side of the slope close to the longitudinal reinforcement slide seat (12) is lower and the other side is higher; When the movable step platform (181) is aligned with the fixed step platform (182) during the lifting process, only one longitudinal reinforcement (21) can be accommodated on each step of the fixed step platform (182).

14. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: There are two groups of reinforcement telescopic arms (19), which are respectively located on both sides above the longitudinal reinforcement slide (12). The telescopic direction of the reinforcement telescopic arms (19) is toward the longitudinal reinforcement slide (12). The top of the reinforcement telescopic arms (19) is provided with an inclined surface, and the end close to the longitudinal reinforcement slide (12) is lower, so that the longitudinal reinforcement (21) dropped on the reinforcement telescopic arms (19) can roll down toward the longitudinal reinforcement slide.

15. The industrial intelligent production equipment for cast-in-situ box beam steel bar components according to claim 14 is characterized in that: A rib dropping sensor (191) is provided at the top end of the rib dropping telescopic arm (19). The rib dropping sensor (191) adopts a Hall sensor, a magnetic sensor or a reflective photoelectric sensor to detect whether a longitudinal rib (21) has fallen.

16. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: The slide locking mechanism (132) is a set of lifting connecting pins, which is used to temporarily fix and connect the two sets of longitudinal reinforcement slides.

17. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: The mesh frame (9) is also provided with a mesh position acquisition camera (95) for acquiring the position of the currently first steel mesh (8) so that the positioning mechanism of the mesh positioning claw (92) can fix the position of the currently first steel mesh (8).

18. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: The block welding device (10) is a multi-joint robotic arm, and a block welding head (104) is provided at the free end of the robotic arm; Alternatively, the block welding device (10) is provided with a block welding gantry (101) that can move in the longitudinal direction, a plurality of block welding carriages (102) are provided on the block welding gantry (101), a welding head lifting device (103) is provided on the block welding carriages (102), and the welding head lifting device (103) is connected to the block welding head (104).

19. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: A block welding point acquisition camera (105) is provided on the block welding gantry (101) or the block welding head (104).

20. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: The longitudinal reinforcement fixing device is provided with a first occlusal head (202) and a second occlusal head (204) arranged relatively to each other, the first occlusal head (202) and the second occlusal head (204) are arranged to slide relative to each other, a plurality of rubber sleeves (203) for the longitudinal reinforcement (21) to pass through are provided between the first occlusal head (202) and the second occlusal head (204), occlusal teeth (205) are provided on opposite sides of the first occlusal head (202) and the second occlusal head (204), and the relative sliding between the first occlusal head (202) and the second occlusal head (204) causes the rubber sleeve (203) to deform, so as to fix the end of the longitudinal reinforcement (21) to the traction frame (201).

21. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: The longitudinal reinforcement fixing device is provided with two sets of movable baffles (211) that can be temporarily fixed. The movable baffles (211) are provided with cavities for the longitudinal reinforcement (21). A plurality of relatively arranged ratchets (212) are provided in the cavities. The ratchets (212) are used to fix the ends of the longitudinal reinforcement (21) and the traction frame (201) when the longitudinal reinforcement (21) passes through.

22. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: A plurality of groups of relatively arranged one-way limiting claws (2071) are provided in the one-way locking device (207). The one-way limiting claws (2071) are connected to the housing of the one-way locking device (207) via a rotating pin (2072). A coil spring (2073) is also provided on the rotating pin (2072) so that the one-way limiting claws (2071) tend to support the traction guide rail (111) in a single direction.

23. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 22, characterized in that: A reset rod (2074) is also provided, and the reset rod (2074) is located between the one-way limiting claw (2071) and the traction guide rail (111) to disengage the one-way limiting claw (2071) from the traction guide rail (111).

24. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 11, characterized in that: It also includes a steel mesh forming system, with movable guide rails (5) provided on both sides, a movable welding gantry (4) provided on the movable guide rails (5), a plurality of movable welding trolleys (42) provided on the movable welding gantry (4), and a liftable welding head provided on the movable welding trolley (42); A steel mesh forming platform (1) is provided between the movable guide rails (5), and a plurality of steel bar positioning clamps (3) are provided on the steel mesh forming platform (1) for fixing the steel bar unit elements (2).

25. The industrialized intelligent production equipment for cast-in-situ box girder steel bar components according to claim 24, characterized in that: A transporting mechanical arm (6) is also provided, and the transporting mechanical arm (6) is used to move the forming platform (1).

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