Steel bar forming production line and method

Abstract

The invention discloses a reinforcing steel bar forming production line and method, and relates to the technical field of reinforcing steel bar forming, the reinforcing steel bar forming production line comprises a reinforcing steel bar bending forming mechanism and a reinforcing steel bar welding positioning mechanism which are sequentially arranged, a mechanical arm conveying mechanism is arranged on one side of the reinforcing steel bar welding positioning mechanism, and a visual welding arm mechanism is arranged on the other side; the steel bar bending forming mechanism comprises a horizontal material bending frame, double machine heads are installed on one side of the horizontal material bending frame, and the machine heads are correspondingly provided with a material turning frame and a material collecting frame. A plurality of horizontal bending material rotating frames are arranged on the other side of the horizontal bending material frame side by side; the steel bar welding and positioning mechanism comprises a welding table, and a plurality of clamping mechanisms are distributed on the welding table. The mechanical arm conveying mechanism comprises a movable mechanical arm, and the mechanical arm is provided with a hand clamp and an electromagnet. The visual welding arm mechanism comprises a movable welding arm, and the welding arm is provided with a welding gun and a visual camera. The high efficiency of steel bar bending is guaranteed, the automation degree is high, and the steel bar forming efficiency is improved; and mechanical vision and a positioning mechanism are combined, so that the steel bar grabbing precision of the mechanical arm can be ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of steel bar forming, and in particular to a steel bar forming production line and method. Background Art

[0002] In order to better improve the efficiency of steel bar forming and processing, many mechanisms for steel bar processing processes have appeared in the prior art, including manual and automatic steel bar bending machines, automated welding arms, etc.; although some equipment has realized basic automation functions, the degree of intelligence still needs to be improved. For example, the phenomena of false welding and leaking welding generated during the processing cannot be discovered and tracked in time, resulting in the fundamental guarantee of product quality. Due to the limited level of equipment automation, many links in the operation process still require manual participation. Some steel bar skeleton machines use traditional relay control, the equipment is relatively simple, the pitch error is large, and the parameters such as welding speed, ring bar pitch and socket angle cannot be adjusted arbitrarily, which limits the processing accuracy and flexibility. When adjusting the processing of stirrups of different sizes, most of them need to be adjusted manually, and the mechanism for clamping the longitudinal bars also needs manual operation, which increases the complexity and labor intensity of the operation.

[0003] Application No. 201910483785.5 discloses a steel bar forming machine for construction, including a main box, a turntable, a limited mechanism, an adjustment frame, etc. The extension of the telescopic end of the electric push rod pushes the rotating shaft and the positioning pin to move outward, separates the positioning pin from the positioning slot 2 inside the positioning cylinder, and drives the rotating shaft to rotate through the rotation of the servo motor. The positioning pin is only engaged with the positioning slot 1 inside the adjustment frame, thereby driving the adjustment frame to rotate. During the rotation process, the angle of the support rod inside the adjustment frame is changed to better adjust the diameter value between each winding block as a whole. Although the steel bar forming machine can accurately adjust the size of the ring steel bar through the adjustment frame, its efficiency is low and manual loading and unloading is required.

[0004] Application No. 202321127794.9 discloses a steel bar forming device for construction, including a shell, an extrusion roller device, an extrusion channel, a bending assembly inside the shell, a driving mechanism, a transmission mechanism and a connecting mechanism, etc. The bending assembly is used to bend the steel bar. Through the operation of the driving mechanism, under the action of the connecting mechanism, reciprocating cleaning is performed on the steel bar; under the action of the transmission mechanism, the steel bar is sprayed with air. Although the bending efficiency is high and dust and impurities on the surface of the steel bar can be removed, it has no relevant PLC control and can only perform a single bend, and the bending angle cannot be changed, and the bending accuracy cannot be controlled.

[0005] Application No. 201410239467.1 discloses a bending mechanism with a movable suspension mechanism for a steel bar forming machine, including a main rod for suspending the bending device, a bending cylinder, a bending head driven by the bending cylinder, a suspension mechanism, a main rod channel, etc. The main rod passes through the main rod channel, and three groups of roller groups in contact with the main rod are arranged in the main rod channel. The roller groups are evenly distributed around the main rod, and each group of roller groups is provided with a roller, which can roll along the length direction of the main rod. Although it is simple to operate and easy to use, it can meet the requirements of the steel bar forming machine for bending steel bars and is convenient for transportation and packaging, but it has certain limitations. Since it is manually operated, it cannot be processed continuously for a long time.

[0006] In summary, the inventors have found that the existing steel bar forming automation equipment has the following problems:

[0007] (1) Generally speaking, the steel bar forming machine can only process steel bars of specific angles and shapes, cannot set bending parameters independently, and has poor ductility;

[0008] (2) The degree of automation of steel bar forming is not high. After completing one process step, manpower is required to transport it to the next process step, and the continuity of processing is not achieved;

[0009] (3) Most of the bending mechanisms of steel bar forming machines are connected by only a single axis, and their design is relatively simple, and the accuracy cannot be guaranteed. Summary of the invention

[0010] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a steel bar forming production line and method, which adopts multiple working procedures to ensure the high efficiency of steel bar bending; can realize automatic transportation between various processes, with a high degree of automation, and improve the efficiency of steel bar forming; combined with mechanical vision and positioning mechanism, it can ensure the accuracy of the robot arm in grasping the steel bar, and during welding, it can reduce the occurrence of false welds and leaked welds.

[0011] In order to achieve the above object, the present invention is implemented through the following technical solutions:

[0012] In a first aspect, an embodiment of the present invention provides a steel bar forming production line, comprising a steel bar bending and forming mechanism and a steel bar welding and positioning mechanism arranged in sequence, wherein a mechanical arm transport mechanism is provided on one side of the steel bar welding and positioning mechanism, and a visual welding arm mechanism is provided on the other side;

[0013] The steel bar bending and forming mechanism includes a horizontal bending material rack, a double machine head is installed on one side of the horizontal bending material rack, and each machine head is correspondingly installed with a turning rack and a receiving rack; a plurality of horizontal bending transfer racks are arranged side by side on the other side of the horizontal bending material rack;

[0014] The steel bar welding positioning mechanism comprises a welding platform, on which a plurality of clamping mechanisms are distributed;

[0015] The mechanical arm transport mechanism comprises a movable mechanical arm, and the mechanical arm is equipped with a hand clamp and an electromagnetic magnet;

[0016] The visual welding arm mechanism comprises a movable welding arm, on which a welding gun and a visual camera are mounted.

[0017] As a further implementation, the machine head includes a machine head body, a fixed clamp block is provided on one side of the machine head body, and the machine head body is connected to the driving mechanism.

[0018] As a further implementation method, the driving mechanism includes a head motor, which is connected to the first large bevel gear, the first large bevel gear is meshed with the second large bevel gear, and a small bevel gear group is connected through an axis on the inner side of the two large bevel gears; the second large bevel gear is installed on the output shaft, and the head body is installed on the top of the output shaft.

[0019] As a further implementation, the welding table is provided with a plurality of welding mechanisms arranged along a first direction and a plurality of welding mechanisms arranged along a second direction, wherein the first direction is perpendicular to the second direction.

[0020] As a further implementation, the welding mechanism includes a hydraulic cylinder and a clamp connected to the hydraulic cylinder.

[0021] As a further implementation, a plurality of positioning mechanisms are installed on the edge of the welding platform, and the positioning mechanisms are used to fix the welding platform.

[0022] As a further implementation, the robot arm is slidably connected to the first slide rail, the welding arm is slidably connected to the second slide rail, and the second slide rail is parallel to the first slide rail.

[0023] As a further implementation, the visual welding arm mechanism is replaced by a visual laser welding mechanism.

[0024] As a further implementation, the visual welding arm mechanism is replaced by a visual arc welding mechanism.

[0025] In a second aspect, an embodiment of the present invention further provides a working method of the steel bar forming production line, comprising:

[0026] The steel bars to be formed are placed on the horizontal bending transfer rack, which is lifted to send the steel bars to the horizontal bending rack, which then transports the steel bars to the two machine heads. After the bending device bends the steel bars, the turning rack lifts the steel bars out of the machine head and collects them in the receiving rack.

[0027] The mechanical arm moves so that the hand clamp is located above the formed steel bar, and the hand clamp grabs the steel bar and absorbs the steel bar through the electromagnetic magnet; the mechanical arm moves in the opposite direction to the steel bar welding positioning mechanism and releases the steel bar;

[0028] The clamping mechanism clamps the steel bar, and the welding gun moves to the welding position under the action of the welding arm to perform welding operations on the steel bar.

[0029] The beneficial effects of the present invention are as follows:

[0030] (1) The present invention includes a steel bar bending and forming mechanism, a robotic arm transportation mechanism, a steel bar welding positioning mechanism and a visual welding arm mechanism. The robotic arm transportation mechanism is arranged on one side of the steel bar welding positioning mechanism, the visual welding arm mechanism is arranged on the other side of the steel bar welding positioning mechanism, and the steel bar bending and forming mechanism is arranged at one end of the steel bar welding positioning mechanism. The steel bars are transferred between the mechanisms through the robotic arm, and the structure is compact. The steel bar forming, transportation, positioning and welding functions are integrated to realize automatic transportation between various processes, with a high degree of automation, thereby improving the steel bar forming efficiency.

[0031] (2) The present invention incorporates the application of mechanical vision and positioning systems, which can ensure the accuracy of the robot arm in grasping the steel bars during transportation and reduce the occurrence of false welds and leaks during welding; the steel bar bending mechanism adopts a double machine head, and cooperates with a horizontal bending rack, a turning rack and a receiving rack. The steel bars are transported to the double machine heads through the horizontal bending rack and turned over to the receiving rack through the turning rack, thereby ensuring the high efficiency of steel bar bending; the driving mechanism of the machine head adopts multiple pairs of gear meshing, so that the precision of steel bar bending can be more accurately controlled; an electromagnetic suction device is designed at the grasping part of the robot arm to ensure stability when grasping the steel bars.

[0032] (3) The welding method of the present invention can be adopted in various forms and has high deformability; an electric cabinet is provided to realize steel bar bending control by inputting steel bar bending parameters. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings in the specification, which constitute a part of the present invention, are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute improper limitations on the present invention.

[0034] Figure 1 It is an axonometric diagram of the overall structure of an embodiment of the present invention;

[0035] Figure 2 Axonometric diagram of the steel bar bending and forming mechanism of the present invention

[0036] Figure 3 for Figure 2 Middle A is a partial enlarged view;

[0037] Figure 4 It is a front view of the steel bar bending and forming mechanism of the present invention;

[0038] Figure 5 This is an enlarged axonometric view of the material turning frame of the steel bar bending and forming mechanism of the present invention;

[0039] Figure 6It is a cross-sectional view of the head of the steel bar bending and forming mechanism of the present invention;

[0040] Figure 7 It is a side axonometric view of the steel bar bending and forming mechanism of the present invention;

[0041] Figure 8 This is an axonometric diagram of the visual robot transport mechanism of the present invention;

[0042] Fig. 9 for Figure 7 Middle B is a partial enlarged view;

[0043] Fig.10 This is an exploded view of the clamping device of the visual robot arm transport mechanism of the present invention;

[0044] Fig.11 It is a side axonometric view of the visual robot arm transport mechanism of the present invention;

[0045] Fig.12 This is an axonometric diagram of the steel bar welding positioning mechanism of the present invention;

[0046] Fig.13 for Fig.12 Middle C is a partial enlarged view;

[0047] Fig.14 This is an axonometric diagram of the automatic welding arm mechanism of the present invention;

[0048] Fig.15 for Fig.14 Middle D is a partial enlarged view;

[0049] Fig.16 It is a side axonometric view of the automatic welding arm mechanism of the present invention;

[0050] Fig.17 This is an axonometric diagram of a laser welding head in Example 3 of the present invention;

[0051] Fig.18 Axonometric view of the arc welding arm in Example 4 of the present invention

[0052] Fig.19 It is a flow chart of the present invention;

[0053] Fig. 20 Workflow for welding starting point identification and positioning;

[0054] Fig.21 Visual servo control structure for welding starting point identification and positioning;

[0055] Among them, Ⅰ, steel bar bending and forming mechanism, Ⅱ, mechanical arm transportation mechanism, Ⅲ, steel bar welding positioning mechanism, Ⅳ, visual welding arm mechanism;

[0056] Ⅰ-1, material collection rack, Ⅰ-2, first machine head, Ⅰ-3, electric cabinet, Ⅰ-4, horizontal bending rack, Ⅰ-5, first turning rack, Ⅰ-6, horizontal bending rack, Ⅰ-7, second machine head, Ⅰ-8, second turning rack, Ⅰ-9, rack, Ⅰ-10, fixed clamp, Ⅰ-11, machine head motor, Ⅰ-12, first large bevel gear, Ⅰ-13, small bevel gear set, Ⅰ-14, second large bevel gear, Ⅰ-15, output shaft, Ⅰ-16, guide wheel bracket, Ⅰ-17, slide plate, Ⅰ-18, guide wheel ; Ⅱ-1, first slide rail, Ⅱ-2, arm seat, Ⅱ-3, first large arm, Ⅱ-4, first small arm, Ⅱ-5, hand clamp, Ⅱ-6, electromagnetic magnet, Ⅱ-7, control circuit, Ⅱ-8, magnetic component, Ⅱ-9, protective cover; Ⅲ-1, positioning mechanism, Ⅲ-2, welding table, Ⅲ-3, clamping mechanism; Ⅳ-1, visual camera, Ⅳ-2, motor, Ⅳ-3, slide rail base, Ⅳ-4, second slide rail, Ⅳ-5, welding base, Ⅳ-6, second large arm, Ⅳ-7, second small arm, Ⅳ-8, welding gun;

[0057] Ⅳ-01-1, aperture, Ⅳ-01-2, laser adapter, Ⅳ-01-3, water cooling block, Ⅳ-01-4, adjustable monitoring circle; Ⅳ-02-1, arc welding base, Ⅳ-02-2, third upper arm, Ⅳ-02-3, third lower arm, Ⅳ-02-4, head arm, Ⅳ-02-5, arc welding gun head. DETAILED DESCRIPTION

[0058] It should be noted that the following detailed descriptions are illustrative and intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meanings as those commonly understood by those skilled in the art to which the present invention belongs.

[0059] Embodiment 1:

[0060] This embodiment provides a steel bar forming production line, such as Figure 1 As shown, it includes a steel bar bending and forming mechanism I, a robotic arm transportation mechanism II, a steel bar welding positioning mechanism III and a visual welding arm mechanism IV. The robotic arm transportation mechanism II is arranged on one side of the steel bar welding positioning mechanism III, the visual welding arm mechanism IV is arranged on the other side of the steel bar welding positioning mechanism III, and the steel bar bending and forming mechanism I is arranged at one end of the steel bar welding positioning mechanism III; the mechanisms transfer steel bars through the robotic arm, and the structure is compact.

[0061] Specifically, Figure 2 , Figure 4 and Figure 7As shown, the steel bar bending and forming mechanism I includes a material receiving rack I-1, a horizontal bending rack I-4, a horizontal bending material transfer rack I-6, a turning rack, a machine head, etc., one side of the horizontal bending rack I-4 is provided with a machine head, a turning rack and a material receiving rack I-1, and the other side is provided with a plurality of horizontal bending material transfer racks I-6 arranged side by side, and one end of the horizontal bending rack I-4 is provided with an electric cabinet I-3. Among them, the horizontal bending rack I-4 includes a rack I-9 and a conveyor belt mechanism installed on the rack I-9, and the conveyor belt mechanism is used to place and convey steel bars.

[0062] In this embodiment, two heads are provided, namely, the first head I-2 and the second head I-7. The first head I-2 is provided with a first turning frame I-5 on one side, and the second head I-7 is provided with a second turning frame I-8 on one side. The first head I-2 and the second head I-7 have the same structure. Figure 3 As shown, the fixed clamp block I-10 is installed on the upper side of the machine head body and is located on one side of the machine head. The fixed clamp blocks I-10 of the two machine heads are located on the side close to each other, that is, the inner side of the machine head, and the turning rack is located on the outer side of the machine head. The fixed clamp blocks I-10 are arranged in pairs, and a steel bar clamping space is formed between the two fixed clamp blocks I-10.

[0063] like Figure 5 As shown, the first material turning rack Ⅰ-5 and the second material turning rack Ⅰ-8 have the same structure. The material turning rack includes a guide wheel bracket Ⅰ-16, a slide plate Ⅰ-17 and a guide wheel Ⅰ-18. One end of the slide plate Ⅰ-17 is hinged to the machine head body, and the other end is connected to a driving component, such as a hydraulic cylinder. The inclination angle of the slide plate Ⅰ-17 is changed under the action of the hydraulic cylinder. The cross-section of the slide plate Ⅰ-17 is arc-shaped to match the cross-section of the steel bar. The guide wheel Ⅰ-18 is installed on the outlet side of the slide plate Ⅰ-17 through the guide wheel bracket Ⅰ-16, and the guide wheel Ⅰ-18 guides the steel bar. The bent steel bars are collected in the receiving rack Ⅰ-1 through the flipping movement of the material turning rack. The structure of the receiving rack Ⅰ-1 is a prior art and will not be described here.

[0064] like Figure 6 As shown, a driving mechanism is installed inside the machine head body, and the driving mechanism includes a machine head motor Ⅰ-11, which is connected to the first large bevel gear Ⅰ-12, and the first large bevel gear Ⅰ-12 is meshed with the second large bevel gear Ⅰ-14. The small bevel gear set Ⅰ-13 is connected to the inner side of the two large bevel gears through an axis; the second large bevel gear Ⅰ-14 is installed on the output shaft I-15, and the machine head body is installed on the top of the output shaft I-15. In this embodiment, multiple pairs of gears are meshed inside the machine head to increase constraints, so that the precision of steel bar bending is more accurate. Among them, the bending mechanism is the existing machine head structure for bending steel bars, which will not be repeated here.

[0065] It should be noted that the "big" and "small" in the large bevel gear and small bevel gear set are relative concepts and do not limit the size of the bevel gears.

[0066] like Figure 8 and Fig.11 As shown, the robot transport mechanism II includes a robot, which is slidably connected to the first slide rail II-1, and the robot is connected to the control circuit II-7. The robot can move along the first slide rail II-1 under the action of the gear rack mechanism driven by the motor. The robot includes an arm seat II-2, a first large arm II-3, and a first small arm II-4 connected in sequence, and each arm is connected through a rotating joint. The end of the first small arm II-4 is equipped with a hand clamp II-5 through a rotating joint; as shown Fig. 9 and Fig.10 As shown, the hand clamp II-5 is provided with an electromagnetic magnet II-6, which is fixed by a magnetic component II-8 and becomes magnetic when powered on; at the same time, a protective cover II-9 is installed on the outside of the electromagnetic magnet II-6 to play a protective role.

[0067] like Fig.12 As shown, the steel bar welding positioning mechanism III includes a welding platform III-2, a positioning mechanism III-1 and a clamping mechanism III-3. A plurality of positioning mechanisms III-1 are evenly distributed along the edge of the welding platform III-2, and the positioning and fixing of the welding platform III-2 are achieved through the positioning mechanism III-1. In this embodiment, the positioning mechanism III-1 includes a positioning plate and anchor bolts installed on the positioning plate, and the welding platform III-2 can be firmly fixed on the ground through the anchor bolts.

[0068] A plurality of clamping mechanisms III-3 are distributed on the upper surface of the welding table III-2. In the present embodiment, the clamping mechanisms III-3 are arranged in two rows, and each row is provided with a plurality of clamping mechanisms III-3 of different numbers; the two rows of clamping mechanisms III-3 have the same orientation, and their clamping directions are along the width direction (first direction) of the welding table III-2. Clamping mechanisms III-3 whose clamping directions are along the length direction (second direction) of the welding table III-2 are respectively provided on both sides of the two rows of clamping mechanisms III-3; this arrangement can reduce slag inclusions, pores, etc. generated during welding. Fig.13 As shown, the clamping mechanism III-3 includes a hydraulic cylinder and a clamp connected to the hydraulic cylinder. When the robotic arm transport mechanism II puts the steel bar into the clamp, the hydraulic cylinder presses the steel bar to improve the subsequent welding accuracy.

[0069] like Fig.14 and Fig.16 As shown, the visual welding arm mechanism IV includes a second slide rail IV-4, a slide rail base IV-3 slidably connected to the second slide rail IV-4, a welding arm is installed on the slide rail base IV-3, and the welding arm includes a welding base IV-5, a second large arm IV-6 and a second small arm IV-7 connected in sequence through a rotating joint; the second slide rail IV-4 is parallel to the first slide rail II-1. Fig.15 As shown, a visual camera IV-1 and a welding gun IV-8 are installed at the end of the second forearm IV-7. The visual camera IV-1 can assist the welding arm to complete autonomous welding work.

[0070] In this embodiment, the visual welding arm mechanism IV is designed as follows:

[0071] The MDH method is used to establish the kinematic model of the six-axis robot arm, and the forward and inverse kinematics are derived based on the kinematic knowledge. Then the robot toolbox in MATLAB is used to perform simulation analysis to verify the correctness of the model.

[0072] Specifically, we first analyze the relationship between each coordinate system and use the checkerboard calibration method and the depth detection function of the LeTV depth camera to complete the calibration of the visual camera IV-1, and obtain the camera's intrinsic parameter matrix, thereby obtaining the conversion relationship between the robotic arm base coordinate system and the image pixel coordinate system; then we analyze the hand-eye calibration principle, use the OpenCV vision library to complete the hand-eye calibration experiment, obtain the external parameter matrix of the visual camera IV-1, and design experiments to evaluate the hand-eye calibration results.

[0073] This embodiment includes steel bar forming, transportation, positioning and welding mechanisms, and adopts multiple working procedures. The steel bar bending mechanism adopts a dual head and a controllable electric cabinet to ensure the high efficiency of steel bar bending. Mechanical vision and positioning mechanisms are added to ensure the accuracy of the mechanical arm in grasping the steel bars during transportation, and to reduce the occurrence of false welds and leaked welds during welding. Through the automated transportation mechanism, automatic transportation between various working procedures can be achieved, thereby improving the efficiency of steel bar forming.

[0074] Embodiment 2:

[0075] This embodiment provides a working method of a steel bar forming production line, using the forming production line described in Example 1, such as Fig.19 As shown, the following steps are included:

[0076] The steel bars to be formed are placed on the horizontal bending material transfer rack Ⅰ-6, and the equipment starts to run. The horizontal bending material transfer rack Ⅰ-6 is lifted up to send the steel bars to the horizontal bending material rack Ⅰ-4. At this time, the horizontal bending material rack Ⅰ-4 will continue to move forward and send the steel bars to the first head Ⅰ-2 and the second head Ⅰ-7. Under the action of the fixed clamps Ⅰ-10 of the two heads, the steel bars are stuck in a straight line; at this time, the first head Ⅰ-2 and the second head Ⅰ-7 bend the steel bars according to the values ​​set in the electric cabinet Ⅰ-3. After bending, the first turning rack Ⅰ-5 and the second turning rack Ⅰ-8 lift the steel bars out of the heads and collect them in the receiving rack Ⅰ-1 through the guide rack of the receiving rack Ⅰ-1.

[0077] The parameters of steel bar bending include bending diameter, bending angle and bending adjustment value. Because the budget length and cutting length of a single steel bar are different, the budget length is calculated according to the outer skin of the steel bar, and the cutting length is calculated according to the central axis of the steel bar. For example, for a steel bar with a budget length of a meter, its cutting length does not need to be a meter, but is less than a meter. This is because the steel bar will become longer during the bending process. If the cutting length is a meter, the final length will exceed a meter. The difference between the budget length and the cutting length is the bending adjustment value of the steel bar, also known as the measurement difference.

[0078] The motor next to the arm seat Ⅱ-2 on the first slide rail Ⅱ-1 of the robotic arm transport mechanism II is started, so that the robotic arm structure moves to the left. At this time, the arm seat Ⅱ-2, the first large arm Ⅱ-3 and the first small arm Ⅱ-4 rotate through the rotary joint to keep the hand clamp Ⅱ-5 above the formed steel bars. Through the action of the control circuit Ⅱ-7, the hand clamp Ⅱ-5 rotates downward and contracts inward to clamp the steel bars. The electromagnetic magnet Ⅱ-6 is energized to absorb the steel bars, and the transportation work is completed; the arm seat Ⅱ-2, the first large arm Ⅱ-3 and the first small arm Ⅱ-4 return to their original state, and the motor reverses to move the robotic arm to the right side of the slide rail Ⅱ-1. Afterwards, the arm seat Ⅱ-2, the first large arm Ⅱ-3 and the first small arm Ⅱ-4 suspend the steel bar above the clamping mechanism Ⅲ-3 in the steel bar welding positioning mechanism III through the action of the rotating joint, and the hand clamp Ⅱ-5 rotates outward counterclockwise. At this time, the electromagnetic magnet Ⅱ-6 has not been powered off, and the steel bar is still being adsorbed. Then the electromagnetic magnet Ⅱ-6 is powered off, and the steel bar falls into the clamping mechanism Ⅲ-3, completing the taking and placing of the steel bar from the forming mechanism.

[0079] The working principle of electromagnetic magnets is based on electromagnetic induction and magnetization. When current passes through the coil of an electromagnet, a magnetic field is generated, which can magnetize ferromagnetic materials (such as steel bars), thereby generating an attractive force. When the current is disconnected, the magnetic field disappears and the attractive force disappears as well.

[0080] When the formed steel bar is placed in the clamping mechanism III-3, the hydraulic pump driven by the engine converts mechanical energy into hydraulic energy; then, high-pressure liquid enters the hydraulic cylinder through the pipeline to push the piston to move; the movement of the piston drives the clamp to achieve clamping or loosening. The whole process is controlled by the hydraulic control system to achieve precise clamping and loosening.

[0081] The hydraulic pumps in the clamping mechanism are distributed at the locations that require welding. Clamping the welding locations can reduce pores, cracks, pits, undercuts, weld nodules, etc. that occur during welding, thereby improving quality and reliability and enabling the welded steel bars to achieve the expected performance.

[0082] The motor IV-2 next to the slide base IV-3 on the second slide rail IV-4 is started, and the welding arm on the right side of the slide rail is moved to the left side. At this time, the welding base IV-5, the second large arm IV-6 and the second small arm IV-7 rotate through the rotating joint to keep the welding gun IV-8 in the welding position. At this time, the welding gun IV-8 automatically searches for the part to be welded through the mechanical vision system, and checks for missing welds, leaking welds and other phenomena after the welding steps are completed. After the inspection is completed, it returns to the initial position through the rotating joint.

[0083] The positioning of welding gun IV-8 to the starting point of the weld is mainly affected by three factors: 1. Mechanical positioning error causes the starting point of the weld to change each time welding, and the starting position of welding gun IV-8 must also change accordingly; 2. Frequent replacement of welding wire requires repositioning of the welding gun, which artificially introduces errors in the alignment of the welding gun with the weld; 3. During the welding process, the direction of the weld is inconsistent with the direction of the walking mechanism, and continuous correction control in the X-axis direction is required, causing the welding gun to deviate from the initial starting point when returning to the starting point of the weld. The visual control algorithm realizes the positioning of the starting point, and its workflow is as follows: Fig.21 As shown:

[0084] The position of welding gun IV-8 in the image space is obtained by identifying the feature points of welding gun IV-8. In addition, during the welding process, the rigid connection between welding gun IV-8 and visual camera IV-1 ensures that the position of welding gun IV-8 remains constant. In order to obtain the deviation between welding gun IV-8 and the weld, it is also necessary to obtain the position of the weld in the image space, that is, the weld position feedback coordinates, which play a decisive role in the success or failure of visual servo control. Therefore, in order to improve the robustness of feedback coordinate recognition, the Hough transform method is used to obtain the weld position feedback coordinates according to the different weld widths.

[0085] First, obtain the edge in the column direction of the image through the following gradient edge detection operator:

[0086] =f[ij a1]+f[ij a2]+f[i j+a2]+f[i j+a1]-2(f[ij b1]+f[i j+b1])

[0087] le(i)=j if>0 and the gradient is maximum at column j,

[0088] b1 <a1<a2 (1)

[0089] In the formula, the three parameters a1, a2, and b1 can be adjusted appropriately according to the width of the weld, so that the edge detection algorithm has robustness and good adaptability. After obtaining the gradient, edge extraction is performed, le is the array storing the edge, and j is the column coordinate of the edge point. After completing the above operation, a center point of a weld is extracted in each row, but due to the presence of a lot of interference in the image, it is necessary to perform Hough transform based on these points to obtain the characteristic straight line of the weld in order to obtain a high-precision straight line

[0090] y=kx+c (2)

[0091] Where k and c are the slope and intercept of the weld characteristic line. The weld straight line characteristic point can be obtained by the following formula:

[0092]

[0093] In the formula, F is the coordinate of the extracted image feature point, which is the intersection of the weld line and the horizontal midline of the image, and is also the feedback coordinate during positioning control. H is the height of the weld image, and x is the coordinate of the feature point when the weld line is perpendicular to the u-axis of the image.

[0094] Get the characteristic point coordinates F of the welding gun torch After the weld position feedback coordinate F, the welding robot controls the welding gun to start automatic adjustment. Its visual control structure is as follows: Fig.21 As shown, in the process of visual control for positioning the starting point of the welding gun, a visual camera is first used to capture an image of the spot welding area to obtain the image coordinates of the welding gun in the spot welding area, and this coordinate is used as the target position for positioning visual servo control.

[0095] Then, the algorithm of formula (1), (2), and (3) is used to collect the image of the weld area in real time to obtain the characteristic coordinates F of the weld, which are compared with the characteristic point coordinates of the welding gun indicating the position of the welding gun. set Previously, the welding robot adjusted the welding gun until the deviation between them was less than the set value F set , the starting point positioning control process of the welding gun ends, and the next step of weld tracking control operation starts at the same time.

[0096] Embodiment 3:

[0097] Based on the above-mentioned embodiment 1, this embodiment makes adjustments to the automated welding mechanism in the last step of the process. The welding method used in embodiment 1 is soldering, which belongs to brazing; in this embodiment, a laser welding head is used to use a laser beam to heat the steel bars with high energy and then weld them. Laser welding technology is suitable for steel bar welding with high welding quality requirements.

[0098] like Fig.17As shown, the visual laser welding mechanism includes an aperture ring IV-01-1, a laser adapter IV-01-2, a water-cooling block IV-01-3, and an adjustable monitoring circle IV-01-4, and the above parts are connected by bolts; the laser is emitted through the laser adapter IV-01-2, and the laser changes direction through reflection. After that, the laser beam is emitted through the aperture ring IV-01-1 and is shot at the part that needs to be welded. At the same time, the water-cooling block IV-01-3 cools down the main working components, and the adjustable monitoring circle IV-01-4 performs intelligent analysis of the parts that need to be welded in real time;

[0099] Laser welding can achieve fast welding with high precision and small deformation. The laser beam is easy to focus, align and guided by optical instruments, and it is easy to achieve precise and controllable micro-area welding, with almost no thermal damage to the area around the weld. In addition, laser welding can be carried out at room temperature or under special conditions, and the welding equipment is simple. At the same time, laser welding can weld two metals with different physical properties (such as different resistances), and has good material adaptability. For the welded area, the metallographic change range of the heat-affected zone is small, and the deformation caused by heat conduction is also the lowest. However, laser welding equipment is expensive, and the energy utilization rate of the laser is low, usually less than 20%. At the same time, high-power lasers consume a lot of expensive He gas when running, which increases production costs. For some metal parts, especially metals with high mechanical stress after deep processing, the workpiece has a high tendency to thermal cracks after welding.

[0100] Embodiment 4:

[0101] Based on the above-mentioned embodiment 1, this embodiment makes adjustments to the automated welding mechanism in the last step of the process. Compared with the previous two welding methods, this embodiment adopts arc welding. Arc welding is a welding process in which the metal to be welded is used as one pole and the welding rod is used as the other pole. An arc is generated when the two poles are close to each other. The heat generated by the arc discharge (commonly known as arc combustion) is used to melt the welding rod and the workpiece together and form a weld after condensation, thereby obtaining a firm joint.

[0102] like Fig.18 As shown, the arc welding arm includes an arc welding base IV-02-1, a third upper arm IV-02-2, a third lower arm IV-02-3, a head arm IV-02-4, and an arc welding gun head IV-02-5, wherein the arc welding base IV-02-1, the third upper arm IV-02-2 and the arc welding lower arm IV-02-3 are all connected by the rotating joint in Example 1, and the arc welding gun head IV-02-5 is connected to the head arm IV-02-4; the arc welding base IV-02-1, the third upper arm IV-02-2 and the arc welding lower arm IV-02-3 cooperate with each other to move the arc welding gun head IV-02-5 to the position where welding is required to complete the welding.

[0103] Arc welding is suitable for welding various steels, non-ferrous metals and alloys, with excellent welding quality; it is easy to achieve full-position automated welding; the heat is concentrated, the molten pool is small, the welding speed is fast, the heat-affected zone is small, and the welding deformation of the workpiece is small; the arc is stable, the spatter is small, the forming is beautiful, and it is suitable for double-sided forming. Another advantage of arc welding is that it produces fewer consumables. Consumables refer to components such as nozzles, contact heads, and gas diffusers. They can greatly affect the quality of the output. With the right consumable strategy and combination of arc welding, costs can be greatly reduced and performance can be improved. However, compared with other welding methods, arc welding has a higher initial cost and is more dangerous, requiring professional operating skills and a range of safety measures. Secondly, the quality of arc welding welds is easily affected by the atmosphere.

[0104] The above description is only the preferred embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A steel bar forming production line, characterized in that: It includes a steel bar bending and forming mechanism and a steel bar welding and positioning mechanism which are arranged in sequence. A mechanical arm transport mechanism is arranged on one side of the steel bar welding and positioning mechanism, and a visual welding arm mechanism is arranged on the other side. The steel bar bending and forming mechanism includes a horizontal bending material rack, a double machine head is installed on one side of the horizontal bending material rack, and each machine head is correspondingly installed with a turning rack and a receiving rack; a plurality of horizontal bending transfer racks are arranged side by side on the other side of the horizontal bending material rack; The steel bar welding positioning mechanism comprises a welding platform, on which a plurality of clamping mechanisms are distributed; The mechanical arm transport mechanism comprises a movable mechanical arm, and the mechanical arm is equipped with a hand clamp and an electromagnetic magnet; The visual welding arm mechanism comprises a movable welding arm, on which a welding gun and a visual camera are mounted.

2. A steel bar forming production line according to claim 1, characterized in that: The machine head comprises a machine head body, a fixing clamp is arranged on one side of the machine head body, and the machine head body is connected to the driving mechanism.

3. A steel bar forming production line according to claim 2, characterized in that: The driving mechanism includes a machine head motor, which is connected to the first large bevel gear, the first large bevel gear is meshed with the second large bevel gear, and a small bevel gear set is connected through an axis on the inner side of the two large bevel gears; the second large bevel gear is installed on the output shaft, and the machine head body is installed on the top of the output shaft.

4. A steel bar forming production line according to claim 1, characterized in that: The welding table is provided with a plurality of welding mechanisms arranged along a first direction and a plurality of welding mechanisms arranged along a second direction, wherein the first direction is perpendicular to the second direction.

5. A steel bar forming production line according to claim 1 or 4, characterized in that: The welding mechanism comprises a hydraulic cylinder and a clamp connected to the hydraulic cylinder.

6. A steel bar forming production line according to claim 1 or 4, characterized in that: A plurality of positioning mechanisms are installed on the edge of the welding platform, and the positioning mechanisms are used to fix the welding platform.

7. A steel bar forming production line according to claim 1, characterized in that: The mechanical arm is slidably connected to the first slide rail, the welding arm is slidably connected to the second slide rail, and the second slide rail is parallel to the first slide rail.

8. A steel bar forming production line according to claim 1, characterized in that: The visual welding arm mechanism is replaced by a visual laser welding mechanism.

9. A steel bar forming production line according to claim 1, characterized in that: The visual welding arm mechanism is replaced by a visual arc welding mechanism.

10. A working method of a steel bar forming production line according to any one of claims 1 to 9, characterized in that: include: The steel bars to be formed are placed on the horizontal bending transfer rack, which is lifted to send the steel bars to the horizontal bending rack, which then transports the steel bars to the two machine heads. After the bending device bends the steel bars, the turning rack lifts the steel bars out of the machine head and collects them in the receiving rack. The mechanical arm moves so that the hand clamp is located above the formed steel bar, and the hand clamp grabs the steel bar and absorbs the steel bar through the electromagnetic magnet; the mechanical arm moves in the opposite direction to the steel bar welding positioning mechanism and releases the steel bar; The clamping mechanism clamps the steel bar, and the welding gun moves to the welding position under the action of the welding arm to perform welding operations on the steel bar.

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