A pipeline building prefabricated slab non-welding system and method

Abstract

The present application relates to the building field prefabricated slab welding technology field, for a kind of assembly line type prefabricated slab unmanned welding system and method, the system includes feeding unit, conveying unit, automatic clamping unit, automatic positioning unit, automatic welding unit, automatic stacking unit and whole line control unit, the automatic clamping unit includes blocking mechanism, front push to position mechanism, jacking support mechanism, station pressing mechanism;The automatic positioning unit is used to take photo to the relative position of reinforcing frame and cement fiber baseboard upper iron sheet hole by 3D vision system, calculates to avoid hole coordinates and transmits to avoid hole coordinates to automatic welding unit;Automatic welding unit, according to the point welding of reinforcing frame and cement fiber baseboard iron sheet assembly to avoid hole coordinates;Automatic stacking unit is used to stack the group welding finished product of cement fiber baseboard and reinforcing frame.The present application can improve the qualified rate of prefabricated slab, improve the production efficiency of prefabricated slab and save labor cost.

Description

Technical Field

[0001] This invention relates to the field of precast building slab welding technology, specifically to an automated unmanned welding system and method for precast building slabs. Background Technology

[0002] The rapid development of modern construction technology has placed higher demands on the strength, structural safety, and construction efficiency of building structures. Precast slabs are the foundation slabs for cast-in-place floor slabs in frame-type building structures. To improve construction efficiency on-site, precast slabs have emerged as a modular structure, replacing manual on-site splicing of steel reinforcement frames to meet the requirements of subsequent cast-in-place floor slab production. Precast slab manufacturers produce precast slabs of specified dimensions according to orders, then transport them to the construction site for assembly between floors, followed by the pouring of concrete to form the floor slabs.

[0003] like Figure 1 As shown, the precast building slab includes a steel reinforcement frame 1 and a cement fiber substrate 2, with a foundation sheet 3 on the cement fiber substrate 2. Currently, the assembly welding of the steel reinforcement frame and the cement fiber substrate involves manual spot welding using a handheld welding gun. The manual welding process for assembling the steel reinforcement frame and the cement fiber substrate includes: S1, manually hoisting the cement fiber substrate to the ground welding area; S2, manually moving the steel reinforcement frame to the cement fiber substrate foundation sheet area; S3, due to deformation of the steel reinforcement frame, there are only partial contact points between the steel reinforcement frame and the foundation sheet, manually spot welding these contact points to fix the steel reinforcement frame; S4, manually using a steel chisel to pry and press the uncontacted points of the steel reinforcement frame to fit it against the foundation sheet, prying with one hand and spot welding with the other. If the deformation is too large, assistance from other personnel is required; S5, repeating S2-S4 four times to complete the spot welding of four steel reinforcement frames. These current technologies have some shortcomings: the product qualification rate is very low because the reliance on manual prying and pressing of the steel reinforcement frame to achieve proper welding results in a low qualification rate, requiring subsequent manual re-welding. Production efficiency is low; welding 5-6 precast slabs (3000*1200 mm) per person per 10 hours is required. Labor intensity is high, and the precast slab business is a concentrated order business; producing thousands or tens of thousands of square meters of precast slabs per unit time requires a large workforce concentrated in a short period. Summary of the Invention

[0004] To address the technical problems existing in the prior art, this invention provides an automated unmanned welding system and method for precast building slabs. By setting up automatic clamping units, automatic positioning units, and automatic welding units, the system can improve the pass rate of precast building slabs, increase the production efficiency of precast building slabs, and save labor costs.

[0005] The objective of this invention can be achieved by adopting the following technical solutions:

[0006] An automated welding system for precast concrete slabs in a production line includes: a feeding unit, a conveying unit, an automatic clamping unit, an automatic positioning unit, an automatic welding unit, an automatic stacking unit, and a line control unit.

[0007] The conveying unit includes a main conveyor line and a stack conveyor line. The main conveyor line is used to convey cement fiber substrates, steel reinforcement frames and their components to various workstations, and to convey the assembled welded products of cement fiber substrates and steel reinforcement frames to the end of the main conveyor line. The stack conveyor line is used to convey the stacked assembled welded products.

[0008] The feeding unit is used to transport the cement fiber substrate and the steel bar frame to the main conveyor line respectively, and match the steel bar frame onto the cement fiber substrate to obtain the cement fiber substrate and steel bar frame assembly.

[0009] The automatic clamping unit includes a blocking mechanism, a forward pushing mechanism, a lifting support mechanism, and a station pressing mechanism. The blocking mechanism and the forward pushing mechanism position the assembly of the cement fiber substrate and the steel bar frame. The lifting support mechanism provides water support to the bottom of the cement fiber substrate. The station pressing mechanism presses the steel bar frame onto the cement fiber substrate, so that the steel bar frame and the surface of the cement fiber substrate are in contact.

[0010] The automatic positioning unit is used to take pictures of the relative positions of the steel frame and the iron hole on the cement fiber substrate through a 3D vision system, calculate the coordinates of the hole to be avoided, and transmit the coordinates of the hole to the automatic welding unit.

[0011] The automatic welding unit performs spot welding on the steel frame and cement fiber substrate sheet assembly according to the avoidance hole coordinates transmitted by the 3D vision system, to obtain the finished welded cement fiber substrate and steel frame.

[0012] The automatic stacking unit is used to stack the welded finished products of cement fiber substrate and steel frame.

[0013] The line control unit is connected to the feeding unit, conveying unit, automatic clamping unit, automatic positioning unit, automatic welding unit, and automatic palletizing unit, respectively, and is used to issue control action commands to the feeding unit, conveying unit, automatic clamping unit, automatic positioning unit, automatic welding unit, and automatic palletizing unit and monitor the operating status in real time.

[0014] Specifically, the main conveyor line is equipped with multiple stations, including: station 1 is the cement fiber board feeding station, station 2 is the cement fiber board matching station with the steel bar frame, station 3 is the cement fiber board and steel bar frame first assembly welding station, station 4 is the cement fiber board and steel bar frame second assembly welding station, stations 5 and 6 are the finished products waiting for sampling inspection station, and station 7 is the finished product stacking and material picking station.

[0015] Specifically, the feeding unit includes: a cement fiber substrate destacking robot and a gripper, a rebar frame handling robot and a gripper, and a rebar frame conveyor line. The cement fiber substrate destacking robot uses its gripper to pick up the cement fiber substrate from the incoming pallet and place it on station 1 of the main conveyor line. The main conveyor line transports the cement fiber substrate from station 1 to station 2. The rebar frame handling robot transports the rebar frame from the rebar frame conveyor line onto the cement fiber substrate.

[0016] Specifically, the blocking mechanism includes a motor and a blocking plate, which are connected by a drive, and the motor and the blocking plate are arranged on the main conveyor line;

[0017] The forward-pushing mechanism includes a motor and a forward-pushing plate, which are connected by a transmission. The motor drives the forward-pushing plate to position the steel frame assembly onto the cement fiber substrate.

[0018] The lifting support mechanism includes a hydraulic lifting device, which is set at workstations 3 and 4. The hydraulic lifting device is installed below the bottom of the cement fiber substrate and is used to support the bottom of the cement fiber substrate upward.

[0019] The workstation clamping mechanism includes multiple sets of clamping cylinders and a gantry fixing frame. The multiple sets of clamping cylinders are fixedly mounted on the gantry fixing frame and are located above the cement fiber substrate and the steel reinforcement frame assembly. Each clamping cylinder includes a cylinder and a cylinder push rod, with the cylinder connected to the cylinder push rod. When the clamping cylinder is working, the cylinder push rod of the clamping cylinder presses down to contact the steel reinforcement frame of the cement fiber substrate and the steel reinforcement frame assembly, so that the steel reinforcement frame is completely attached to the surface of the cement fiber substrate.

[0020] Specifically, the 3D vision system includes multiple 3D industrial cameras and an industrial control computer. The multiple 3D industrial cameras are connected to the industrial control computer and are installed at different positions on the gantry frame. The 3D industrial cameras are located above the steel frame and cement fiber substrate assembly.

[0021] Specifically, the automatic welding unit includes multiple welding robots, a welding power source, and a welding control system. The welding robots are electrically connected to the welding power source and the welding control system, respectively. The multiple welding robots are respectively set on both sides of the workstations 3 and 4 of the main conveyor line.

[0022] Specifically, the automatic palletizing unit includes a palletizing robot, a hand gripper, and a transfer station. The palletizing robot picks up qualified welded finished products from station 7 and pallets them onto a qualified pallet; qualified welded finished products that need to be flipped and palletized are placed on the transfer station, picked up in the opposite direction, and palletized onto a qualified pallet; unqualified products are palletized onto an unqualified pallet.

[0023] A method for unmanned welding of precast building slabs in an assembly line manner, comprising:

[0024] S1. The cement fiber substrate is transported from the predetermined stack to station 1 of the main conveyor line by the cement fiber substrate destacking robot. The cement fiber substrate is centered and positioned at station 1. The cement fiber substrate is then transported to station 2 of the main conveyor line and blocked and positioned by the blocking mechanism.

[0025] S2. The steel bar frame is transported from the steel bar frame conveyor line to station 2 of the main conveyor line by the handling robot. The steel bar frame and the cement fiber substrate are positioned and matched by the forward pushing mechanism to form the cement fiber substrate and steel bar frame assembly.

[0026] S3. The cement fiber substrate and the steel reinforcement frame assembly are transported to station 3 of the main conveyor line. The bottom of the cement fiber substrate is supported by the lifting support mechanism, and the steel reinforcement frame is pressed onto the cement fiber substrate by the station pressing mechanism, so that the steel reinforcement frame and the cement fiber substrate are in contact.

[0027] S4. Take pictures of the relative positions of the steel frame and the iron sheet holes on the cement fiber substrate using a 3D vision system; calculate the relative positions of the steel frame and the iron sheet holes on the cement fiber substrate, and transmit the hole avoidance coordinates to the automatic welding unit; the automatic welding unit performs the first spot welding on the steel frame and the iron sheet assembly of the cement fiber substrate according to the hole avoidance coordinates transmitted by the 3D vision system to obtain the semi-finished product of the cement fiber substrate and the steel frame.

[0028] S5. The semi-finished product of the cement fiber substrate and the steel frame is transported to station 4 of the main conveyor line. The automatic welding unit performs a second spot welding on the steel frame and the sheet metal assembly of the cement fiber substrate according to the avoidance hole coordinates transmitted by the 3D vision system to obtain the finished product of the cement fiber substrate and the steel frame.

[0029] S6. The welded finished products of cement fiber substrate and steel frame are transported to station 5 and station 6 of the main conveyor line. The welded finished products are randomly inspected to determine whether they are qualified welded finished products.

[0030] The S7 palletizing robot picks up qualified welded products from station 7 and pallets them onto a qualified pallet; it then places qualified welded products that need to be flipped and palletized onto a transfer station, picks them up in the opposite direction, and pallets them onto a qualified pallet; and it pallets unqualified products onto an unqualified pallet.

[0031] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0032] This invention provides an automated welding system and method for precast concrete slabs in a production line. The system positions the assembly of the cement fiber substrate and the reinforcing steel frame using a blocking mechanism and a forward-pushing mechanism. A lifting support mechanism provides hydraulic support to the bottom of the cement fiber substrate, and a station clamping mechanism presses the reinforcing steel frame firmly onto the cement fiber substrate, ensuring close contact between the steel frame and the substrate surface. This overcomes the problems associated with manual welding, where workers use steel rods to pry and press the steel frame at uncontacted points to adhere it to the foundation sheet metal, requiring assistance from other personnel if excessive deformation occurs.

[0033] The relative positions of the steel reinforcement frame and the iron sheet holes on the cement fiber substrate are photographed using a 3D vision system. The relative positions of the steel reinforcement frame and the iron sheet holes on the cement fiber substrate are calculated, and the 3D vision system transmits the hole avoidance coordinates to the automatic welding unit. The automatic welding unit performs spot welding on the steel reinforcement frame and the iron sheet assembly of the cement fiber substrate according to the hole avoidance coordinates transmitted by the 3D vision system, and obtains the welded finished product of the cement fiber substrate and the steel reinforcement frame. This can improve the qualification rate of precast slabs for buildings, increase the production efficiency of precast slabs for buildings, and save labor costs. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0035] Figure 1 This is a schematic diagram of the precast concrete slab structure of a building in an embodiment of the present invention;

[0036] Figure 2 This is a schematic diagram of the overall structure of an unmanned welding system for prefabricated building panels in an embodiment of the present invention;

[0037] Figure 3 This is a site layout diagram of an automated prefabricated building panel welding system according to an embodiment of the present invention.

[0038] Figure 4 This is a schematic diagram of the main conveyor line station in an embodiment of the present invention;

[0039] Figure 5 This is a schematic diagram of the cement fiber substrate destacking robot and hand gripper application layout in an embodiment of the present invention;

[0040] Figure 6 This is a schematic diagram of the layout of the rebar rack handling robot and hand gripper in an embodiment of the present invention;

[0041] Figure 7This is a schematic diagram of the blocking mechanism in an embodiment of the present invention;

[0042] Figure 8 This is a schematic diagram of the lifting support mechanism in an embodiment of the present invention;

[0043] Figure 9 This is a schematic diagram of the workstation clamping mechanism in an embodiment of the present invention;

[0044] Figure 10 This is a schematic diagram showing the relative positions of the steel reinforcement frame and the iron sheet holes on the cement fiber substrate in an embodiment of the present invention.

[0045] The diagram is labeled as follows: 1-Rebar frame, 2-Cement fiber substrate, 3-Foundation sheet metal, 4-Incoming pallet, 5-Cement fiber substrate destacking robot, 51-Hand gripper of cement fiber substrate destacking robot, 6-Rebar frame conveyor line, 7-Rebar frame handling robot, 71-Hand gripper of rebar frame handling robot, 8-Welding control system, 9-Welding robot, 10-Assembled finished product inspection station, 11-Palletizing robot, 12-Pallet conveyor line, 13-Workstation 1, 14-Workstation 2, 15-Workstation 3, 16-Workstation 4, 17-Workstation 5, 18-Workstation 6, 19-Workstation 7, 20-Motor, 21-Blocking plate, 22-Hydraulic cylinder, 23-Supporting structure, 24-Clamping cylinder, 25-Gantry fixing frame, 26-Sheet metal hole, 27-Weldable position. Detailed Implementation

[0046] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments, and the implementation of the present invention is not limited thereto. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0047] Example 1:

[0048] like Figure 2 As shown, an unmanned welding system for precast building slabs in an assembly line configuration includes: a conveying unit, a feeding unit, an automatic clamping unit, an automatic positioning unit, an automatic welding unit, an automatic stacking unit, and a line control unit. The conveying unit, feeding unit, automatic clamping unit, automatic positioning unit, automatic welding unit, and automatic stacking unit are all electrically connected to the line control unit. Wherein:

[0049] The conveying unit includes a main conveyor line and a stacking conveyor line. The main conveyor line is used to transport cement fiber substrates, steel reinforcement frames, and their components to various workstations to complete their predetermined functions, and to transport the assembled cement fiber substrates and steel reinforcement frames to the end of the main conveyor line for stacking. In this embodiment, as shown... Figure 3The diagram shows a layout of an automated welding system for precast concrete slabs in a production line. The system includes a material pallet 4 for the feeding unit, a cement fiber substrate destacking robot 5, a gripper 51 for the cement fiber substrate destacking robot, a rebar conveyor line 6, a rebar handling robot 7, and a gripper 71 for the rebar handling robot; a welding control system 8 and a welding robot 9 for the automatic welding unit; a finished product inspection station 10; and a palletizing robot 11 and a material conveyor line 12 for the automatic palletizing unit. Figure 4 The diagram shows the main conveyor line, which includes 7 stations. Station 1 is the cement fiberboard feeding station, used for feeding cement fiberboard. Station 2 is the cement fiberboard and rebar frame matching station, used for feeding rebar frames and matching and positioning them with the cement fiberboard to obtain the cement fiberboard and rebar frame assembly. Station 3 is the cement fiberboard and rebar frame primary welding station, used for the first preliminary welding of the cement fiberboard and rebar frame assembly by an automatic welding unit to obtain the preliminary welded part of the cement fiberboard and rebar frame. Station 4 is the cement fiberboard and rebar frame secondary welding station, used for clamping the unit cement fiberboard and rebar frame by automatic clamping and performing the second full welding of the cement fiberboard and rebar frame to obtain the welded finished product of the cement fiberboard and rebar frame. Stations 5 and 6 are the finished product sampling inspection stations, used for sampling inspection of the welded finished products of the cement fiberboard and rebar frame to obtain qualified and unqualified products. Station 7 is the finished product stacking and material retrieval station, where a stacking robot stacks qualified products.

[0050] The material stacking conveyor line is used to transport the stacked welded finished products. It includes empty pallet loading position, empty pallet temporary storage position, stacking position, full stack temporary storage position, and full stack unloading position, realizing the functions of empty pallet loading, empty pallet temporary storage, stacking of cement fiber substrate and steel bar frame welded finished products, and storage of full stacks.

[0051] The loading unit is used to transport cement fiber substrates and rebar frames to the main conveyor line, and to match the rebar frames onto the cement fiber substrates. Specifically, the loading unit includes: a cement fiber substrate destacking robot 5 and a gripper 51, a rebar frame conveyor line 6, and a rebar frame handling robot 7 and a gripper 71. In this embodiment, the cement fiber substrate is placed on the incoming pallet 4. The cement fiber substrate destacking robot 5 uses the gripper 51 to pick up the cement fiber substrate from the incoming pallet and place it onto the main conveyor line. The rebar frame handling robot 7 transports four rebar frames from the rebar frame conveyor line to the cement fiber substrate in two stages. Figure 5 The diagram shows a layout of the cement fiber substrate destacking robot and its hand gripper in an embodiment of the present invention. Figure 6 The diagram shows a schematic layout of the rebar rack handling robot and its hand gripper in an embodiment of the present invention.

[0052] In this embodiment, the cement fiber substrate destacking robot and the hand gripper realize the destacking of cement fiber substrates from pallets to station 1 of the conveying unit. The main conveyor line transports the cement fiber substrates from station 1 to station 2. The steel bar frame handling robot and the hand gripper realize the transportation of 4 steel bar frames from the steel bar frame conveyor line to station 2 of the conveying unit in two batches to match the cement fiber substrates.

[0053] The automatic clamping unit includes a blocking mechanism, a forward pushing mechanism, a lifting support mechanism, and a station clamping mechanism. The blocking mechanism and the forward pushing mechanism position the assembly of the cement fiber substrate and the rebar frame. The lifting support mechanism and the station clamping mechanism press the rebar frame onto the cement fiber substrate, so that the rebar frame and the cement fiber substrate surface are in contact.

[0054] Specifically, the blocking mechanism is used to prevent the cement fiber substrate and the rebar frame assembly in a discrete state from reaching the conveyor station, so that the cement fiber substrate and the rebar frame assembly stop after reaching the predetermined position. For example... Figure 7 As shown in the schematic diagram of the blocking mechanism, the blocking mechanism includes a blocking plate 20 and a motor 21. The motor and the blocking plate are connected by a drive. The motor and the blocking plate are set on the main conveyor line. When the blocking plate is perpendicular to the main conveyor line by controlling the motor, the blocking mechanism is in the blocking state; when the blocking plate is parallel to the main conveyor line by controlling the motor, the blocking mechanism is in the passing state.

[0055] The forward-pushing positioning mechanism includes a motor and a forward-pushing plate, which are connected by a transmission. The motor drives the forward-pushing plate to position the steel frame assembly onto the cement fiber substrate, which can meet the positioning requirements of cement fiber substrates within a certain range.

[0056] The lifting support mechanism includes a hydraulic lifting device, which is installed at workstations 3 and 4. The hydraulic lifting device is mounted below the bottom of the cement fiber substrate and is used to support the bottom of the cement fiber substrate upwards. The hydraulic lifting device includes a hydraulic cylinder 22, inside which is a telescopic rod. The end of the telescopic rod away from the hydraulic cylinder is fixedly connected to a support structure 23. The hydraulic cylinder is fixed to a base bracket. The telescopic rod, connected to the support structure, supports the bottom of the cement fiber substrate upwards, ensuring that the surface of the cement fiber substrate does not deform when the workstation clamping mechanism clamps and positions the reinforcing steel frame. Figure 8 The diagram shows a lifting support mechanism.

[0057] like Figure 9As shown in the schematic diagram of the workstation clamping mechanism, the workstation clamping mechanism includes multiple sets of clamping cylinders 24 and a gantry fixing frame 25. The multiple sets of clamping cylinders are fixedly mounted on the gantry fixing frame and are located above the cement fiber substrate and rebar frame assembly. Each clamping cylinder includes a cylinder and a cylinder push rod, with the cylinder connected to the cylinder push rod. When the clamping cylinder is working, the cylinder push rod of the clamping cylinder presses down to contact the rebar frame of the cement fiber substrate and rebar frame assembly, allowing the rebar frame to fully adhere to the surface of the cement fiber substrate.

[0058] In this embodiment, at workstations 3 and 4, the hydraulic lifting device raises the cement fiber substrate and the steel reinforcement frame. When the cement fiber substrate and the steel reinforcement frame are pressed and positioned, the E-plate surface of the cement fiber substrate is kept undeformed. The cylinder push rod of the pressing cylinder presses down and contacts the steel reinforcement frame of the cement fiber substrate and steel reinforcement frame assembly, so that the steel reinforcement frame is completely attached to the substrate surface.

[0059] The automatic positioning unit is used to take pictures of the relative positions of the steel frame and the iron hole on the cement fiber substrate using a 3D vision system; after calculating the relative positions of the steel frame and the iron hole on the cement fiber substrate, the 3D vision system transmits the hole coordinates to the automatic welding unit.

[0060] Specifically, the 3D vision system includes multiple 3D industrial cameras and an industrial control computer. The multiple 3D industrial cameras are connected to the industrial control computer and are installed at different positions on the gantry frame. The 3D industrial cameras are positioned above the steel reinforcement frame and cement fiber substrate assembly. The 3D industrial cameras take pictures of the relative positions of the metal holes on the steel reinforcement frame and cement fiber substrate and transmit the images to the industrial control computer. For example... Figure 10 The diagram shows the relative positions of the rebar frame and the iron sheet holes on the cement fiber substrate. Since the iron sheet holes on the cement fiber substrate are mesh-like, and the iron sheet is embedded in the substrate, when the rebar is to be spot-welded onto the iron sheet, it's necessary to avoid certain iron sheet holes (e.g., cement material). This requires calculating the coordinates of the iron sheet hole 26, thus obtaining the avoidance hole coordinates. The industrial control computer calculates the avoidance hole coordinates based on the image transmitted by the 3D industrial camera. The industrial control computer then transmits these coordinates to the automatic welding unit, guiding the welding robot in the automatic welding unit to perform spot welding, fixing the rebar frame to the weldable point 27 on the iron sheet of the cement fiber substrate.

[0061] The automated welding unit includes multiple welding robots, a welding power source, and a welding control system. The welding robots are electrically connected to both the welding power source and the welding control system. The welding robots are positioned on both sides of stations 3 and 4 on the main conveyor line. Specifically, each welding robot includes a robot body, a wire feeder, and a welding torch. Eight welding robots are located on both sides of stations 3 and 4 on the conveyor line. Guided by a 3D vision system, they perform spot welding on the steel reinforcement frame and the steel sheet of the cement fiber substrate, assembling them into a finished welded assembly of the cement fiber substrate and the steel reinforcement frame. The welded assembly continues to be conveyed to stations 5 and 6 on the main conveyor line. Stations 5 and 6 are for random inspection of the welded assembly; manual random inspection is conducted to determine if the welded assembly is qualified.

[0062] The automated palletizing unit includes a palletizing robot, a hand gripper, and a transfer station. The welded finished products of cement fiber substrate and steel reinforcement frame are transported to station 7 of the main conveyor line for positioning. The palletizing robot picks up qualified welded finished products from station 7 and stacks them onto a qualified pallet. Qualified welded finished products that need to be flipped are placed on the transfer station, picked up in the opposite direction, and stacked onto a qualified pallet. Unqualified products are stacked onto an unqualified pallet, completing the entire production process.

[0063] The entire production line control unit is connected to the feeding unit, conveying unit, automatic clamping unit, automatic positioning unit, automatic welding unit, and automatic palletizing unit. It issues control commands to these units and monitors their operational status in real time. Specifically, the control unit includes a central control cabinet, a touch screen, a PLC control system, and a display screen. It sends action commands to each execution unit and monitors the operational status, production order status, and alarm information of each unit in real time.

[0064] This embodiment provides an unmanned welding system for precast building slabs in an assembly line format. Based on a production scale of 3000*1200 precast slabs, the unmanned welding production line of this invention can produce 600 slabs per 10 hours, requiring one person to manually replenish the rebar frame; or 50 slabs per 10 hours with 10 people; this is more than 10 times the capacity of manual welding. The unmanned welding production line of this invention achieves a precast slab pass rate of over 99%; compared to over 80% for manually welded precast slabs. This unmanned welding production line is not limited by personnel and can safeguard production orders. Overall, this invention provides an unmanned welding system for precast building slabs in an assembly line format, which can improve the production efficiency of precast building slabs, save labor costs, and increase the pass rate of precast building slabs.

[0065] Based on the above-mentioned unmanned welding system for precast building slabs in an assembly line, the present invention also provides an unmanned welding method for precast building slabs in an assembly line, comprising the following steps:

[0066] S1. The cement fiber substrate is transported from the predetermined stack to station 1 of the main conveyor line by the cement fiber substrate destacking robot. The cement fiber substrate is centered and positioned at station 1. The cement fiber substrate is then transported to station 2 of the main conveyor line and blocked and positioned by the blocking mechanism.

[0067] S2. The steel bar frame is transported from the steel bar frame conveyor line to station 2 of the main conveyor line by the handling robot. The steel bar frame and the cement fiber substrate are positioned and matched by the forward pushing mechanism to form the cement fiber substrate and steel bar frame assembly.

[0068] S3. The cement fiber substrate and the steel bar frame assembly are transported to station 3 of the main conveyor line. The bottom of the cement fiber substrate is supported by the lifting support mechanism, and the steel bar frame is pressed onto the cement fiber substrate by the station pressing mechanism, so that the steel bar frame and the cement fiber substrate surface are in contact.

[0069] Specifically, station 3 is the first welding station for cement fiber substrate and steel bar frame. A hydraulic lifting device is installed at the bottom of the cement fiber substrate to raise it, and eight clamping cylinders are installed above the steel bar frame to press down and fix the steel bar frame and cement fiber substrate assembly.

[0070] S4. Take pictures of the relative positions of the steel reinforcement frame and the iron sheet holes on the cement fiber substrate using a 3D vision system; calculate the relative positions of the steel reinforcement frame and the iron sheet holes on the cement fiber substrate, and transmit the hole avoidance coordinates to the automatic welding unit; the automatic welding unit performs the first spot welding on the steel reinforcement frame and the iron sheet assembly of the cement fiber substrate according to the hole avoidance coordinates transmitted by the 3D vision system, and obtains the semi-finished product of the cement fiber substrate and the steel reinforcement frame.

[0071] Specifically, two industrial cameras suspended above station 3 of the main conveyor line take pictures of the steel frame and the iron sheet holes of the cement fiberboard foundation. The positioning coordinates are sent to four welding robots through the system algorithm. Under visual guidance, the four welding robots on station 3 of the main conveyor line spot weld the cement fiberboard and steel frame assembly, complete the spot welding work of the component part, and produce semi-finished components.

[0072] S5. The semi-finished product of the cement fiber substrate and the steel frame is transported to station 4 of the main conveyor line. The automatic welding unit performs a second spot welding on the steel frame and the sheet metal assembly of the cement fiber substrate according to the avoidance hole coordinates transmitted by the 3D vision system, so as to obtain the finished product of the cement fiber substrate and the steel frame.

[0073] Specifically, station 4 is the second welding station for the cement fiber substrate and the steel reinforcement frame. A hydraulic lifting device is installed at the bottom of the cement fiber substrate to raise it, and eight clamping cylinders are installed above the steel reinforcement frame to press down and fix the steel reinforcement frame and cement fiber substrate assembly. Four welding robots on station 4 of the main conveyor line perform spot welding on the semi-finished assembly under vision guidance, complete the component spot welding work, and produce the finished cement fiber substrate and steel reinforcement frame assembly.

[0074] S6. The assembled and welded products of cement fiber substrate and steel frame are transported to station 5 and station 6 of the main conveyor line. Station 5 and station 6 are the sampling inspection stations for the assembled and welded products. The sampled and welded products are inspected to determine whether they are qualified assembled and welded products.

[0075] S7. The palletizing robot picks up qualified welded finished products from station 7 and stacks them onto a qualified pallet. Station 7 is the finished product palletizing and material picking position. Qualified welded finished products that need to be flipped and stacked are placed on the transfer table, picked up in the opposite direction, and stacked onto a qualified pallet. Unqualified products are stacked onto unqualified pallets, completing the entire production process.

[0076] In summary, the present invention provides an automated welding system and method for precast concrete slabs in a production line. This system positions the assembly of the cement fiber substrate and the reinforcing steel frame using a blocking mechanism and a forward-pushing mechanism. A lifting support mechanism provides hydraulic support to the bottom of the cement fiber substrate, and a station clamping mechanism presses the reinforcing steel frame firmly onto the cement fiber substrate, ensuring close contact between the steel frame and the substrate surface. This overcomes the problems associated with manual welding, where manual methods involve using a steel chisel to pry and press the steel frame at uncontacted points to adhere it to the foundation sheet metal, requiring assistance from other personnel if excessive deformation occurs. The relative positions of the steel reinforcement frame and the iron sheet holes on the cement fiber substrate are photographed using a 3D vision system. The relative positions of the steel reinforcement frame and the iron sheet holes on the cement fiber substrate are calculated, and the 3D vision system transmits the hole avoidance coordinates to the automatic welding unit. The automatic welding unit performs spot welding on the steel reinforcement frame and the iron sheet assembly of the cement fiber substrate according to the hole avoidance coordinates transmitted by the 3D vision system, and obtains the welded finished product of the cement fiber substrate and the steel reinforcement frame. This can improve the qualification rate of precast slabs for buildings, increase the production efficiency of precast slabs for buildings, and save labor costs.

[0077] The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of the present invention shall be considered equivalent substitutions and shall be included within the protection scope of the present invention.

Claims

1. An unmanned welding system for prefabricated building slabs in an assembly line manner, characterized in that, It includes a feeding unit, a conveying unit, an automatic clamping unit, an automatic positioning unit, an automatic welding unit, an automatic palletizing unit, and a complete production line control unit; The conveying unit includes a main conveyor line and a stack conveyor line. The main conveyor line is used to convey cement fiber substrates, steel bars and their components to various workstations, and to convey the assembled cement fiber substrates and steel bars to the end of the main conveyor line. The stack conveyor line is used to convey the assembled cement fiber substrates and steel bars after stacking. The feeding unit is used to transport the cement fiber substrate and the steel bar frame to the main conveyor line respectively, and match the steel bar frame onto the cement fiber substrate to obtain the cement fiber substrate and steel bar frame assembly. The automatic clamping unit includes a blocking mechanism, a forward pushing mechanism, a lifting support mechanism, and a station pressing mechanism. The blocking mechanism and the forward pushing mechanism position the assembly of the cement fiber substrate and the steel bar frame. The lifting support mechanism provides water support to the bottom of the cement fiber substrate. The station pressing mechanism presses the steel bar frame onto the cement fiber substrate, so that the steel bar frame and the surface of the cement fiber substrate are in contact. The automatic positioning unit is used to take pictures of the relative positions of the steel frame and the iron hole on the cement fiber substrate through the 3D vision system; calculate the relative positions of the steel frame and the iron hole on the cement fiber substrate, and transmit the hole coordinates to the automatic welding unit. The automatic welding unit performs spot welding on the steel frame and cement fiber substrate sheet assembly according to the avoidance hole coordinates transmitted by the 3D vision system, to obtain the finished welded cement fiber substrate and steel frame. The automatic stacking unit is used to stack the welded finished products of cement fiber substrate and steel frame. The entire production line control unit is connected to the feeding unit, conveying unit, automatic clamping unit, automatic positioning unit, automatic welding unit, and automatic palletizing unit, respectively, and is used to issue control action commands to the feeding unit, conveying unit, automatic clamping unit, automatic positioning unit, automatic welding unit, and automatic palletizing unit and monitor the operating status in real time. The main conveyor line has multiple workstations, including: workstation 1 is for cement fiberboard feeding; workstation 2 is for matching cement fiberboard substrates with steel reinforcement frames; workstation 3 is for the first welding of cement fiberboard substrates and steel reinforcement frames; workstation 4 is for the second welding of cement fiberboard substrates and steel reinforcement frames; workstations 5 and 6 are for finished products awaiting inspection; and workstation 7 is for finished product stacking and material retrieval. A cement fiberboard substrate destacking robot transports the cement fiberboard substrates from the predetermined stack to workstation 1 on the main conveyor line. At workstation 1, the cement fiberboard substrates are centered and positioned, and water... The cement fiber substrate continues to be transported to station 2 of the main conveyor line, where it is positioned by a blocking mechanism. A handling robot transports the rebar frame from the rebar frame conveyor line to station 2 of the main conveyor line. A forward-pushing mechanism positions and matches the rebar frame with the cement fiber substrate to form a cement fiber substrate and rebar frame assembly. The cement fiber substrate and rebar frame assembly is transported to station 3 of the main conveyor line. A lifting support mechanism provides water support to the bottom of the cement fiber substrate. A station pressing mechanism presses the rebar frame onto the cement fiber substrate, allowing the rebar frame and the cement fiber substrate surface to adhere.

2. The unmanned welding system for prefabricated building slabs in an assembly line manner according to claim 1, characterized in that, The feeding unit includes: a cement fiber substrate destacking robot and a gripper, a rebar frame handling robot and a gripper, and a rebar frame conveyor line. The cement fiber substrate destacking robot uses its gripper to pick up the cement fiber substrate from the incoming pallet and place it on station 1 of the main conveyor line. The main conveyor line transports the cement fiber substrate from station 1 to station 2. The rebar frame handling robot transports the rebar frame from the rebar frame conveyor line onto the cement fiber substrate.

3. The unmanned welding system for prefabricated building slabs in an assembly line manner according to claim 1, characterized in that, The blocking mechanism includes a motor and a blocking plate, which are connected by a drive, and are arranged on the main conveyor line. The forward-pushing mechanism includes a motor and a forward-pushing plate, which are connected by a transmission. The motor drives the forward-pushing plate to position the steel frame assembly onto the cement fiber substrate. The lifting support mechanism includes a hydraulic lifting device, which is set at workstations 3 and 4. The hydraulic lifting device is installed below the bottom of the cement fiber substrate and is used to support the bottom of the cement fiber substrate upward. The workstation clamping mechanism includes multiple sets of clamping cylinders and a gantry fixing frame. The multiple sets of clamping cylinders are fixedly mounted on the gantry fixing frame and are located above the cement fiber substrate and the steel reinforcement frame assembly. Each clamping cylinder includes a cylinder and a cylinder push rod, with the cylinder connected to the cylinder push rod. When the clamping cylinder is working, the cylinder push rod of the clamping cylinder presses down to contact the steel reinforcement frame of the cement fiber substrate and the steel reinforcement frame assembly, so that the steel reinforcement frame is completely attached to the surface of the cement fiber substrate.

4. The unmanned welding system for prefabricated building slabs in an assembly line manner according to claim 3, characterized in that, The 3D vision system includes multiple 3D industrial cameras and an industrial control computer. The multiple 3D industrial cameras are connected to the industrial control computer and are installed at different positions on the gantry frame. The 3D industrial cameras are located above the steel frame and cement fiber substrate assembly.

5. The unmanned welding system for prefabricated building slabs in an assembly line manner according to claim 4, characterized in that, The automatic welding unit includes multiple welding robots, a welding power source, and a welding control system. The welding robots are electrically connected to the welding power source and the welding control system, respectively. The multiple welding robots are respectively set on both sides of the workstations 3 and 4 of the main conveyor line.

6. The unmanned welding system for prefabricated building slabs in an assembly line manner according to claim 1, characterized in that, The automatic palletizing unit includes a palletizing robot, a hand gripper, and a transfer station. The palletizing robot picks up qualified welded finished products from station 7 and stacks them onto a qualified pallet. Qualified welded finished products that need to be flipped and stacked are placed on the transfer station, picked up in the opposite direction, and stacked onto a qualified pallet. Unqualified products are stacked onto an unqualified pallet.

7. A method for unmanned welding of precast building slabs in an assembly line, implemented based on the unmanned welding system for precast building slabs in an assembly line as described in any one of claims 1-6, characterized in that, include: S1. The cement fiber substrate is transported from the predetermined stack to station 1 of the main conveyor line by the cement fiber substrate destacking robot. The cement fiber substrate is centered and positioned at station 1. The cement fiber substrate is then transported to station 2 of the main conveyor line and blocked and positioned by the blocking mechanism. S2. The steel bar frame is transported from the steel bar frame conveyor line to station 2 of the main conveyor line by the handling robot. The steel bar frame and the cement fiber substrate are positioned and matched by the forward pushing mechanism to form the cement fiber substrate and steel bar frame assembly. S3. The cement fiber substrate and the steel reinforcement frame assembly are transported to station 3 of the main conveyor line. The bottom of the cement fiber substrate is supported by the lifting support mechanism, and the steel reinforcement frame is pressed onto the cement fiber substrate by the station pressing mechanism, so that the steel reinforcement frame and the cement fiber substrate are in contact. S4. Take pictures of the relative positions of the steel frame and the iron sheet holes on the cement fiber substrate using a 3D vision system; calculate the relative positions of the steel frame and the iron sheet holes on the cement fiber substrate, and transmit the hole avoidance coordinates to the automatic welding unit; the automatic welding unit performs the first spot welding on the steel frame and the iron sheet assembly of the cement fiber substrate according to the hole avoidance coordinates transmitted by the 3D vision system to obtain the semi-finished product of the cement fiber substrate and the steel frame. S5. The semi-finished product of the cement fiber substrate and the steel frame is transported to station 4 of the main conveyor line. The automatic welding unit performs a second spot welding on the steel frame and the sheet metal assembly of the cement fiber substrate according to the avoidance hole coordinates transmitted by the 3D vision system to obtain the finished product of the cement fiber substrate and the steel frame. S6. The welded finished products of cement fiber substrate and steel frame are transported to station 5 and station 6 of the main conveyor line. The welded finished products are randomly inspected to determine whether they are qualified welded finished products. The S7 palletizing robot picks up qualified welded products from station 7 and pallets them onto a qualified pallet; it then places qualified welded products that need to be flipped and palletized onto a transfer station, picks them up in the opposite direction, and pallets them onto a qualified pallet; and it pallets unqualified products onto an unqualified pallet.

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