Universal flexible integrated prestress positioning mesh production method

Abstract

The invention relates to the technical field of reinforcing mesh production, in particular to a universal flexible integrated prestress positioning mesh production method which comprises the steps that longitudinal reinforcing steel bar rolls and transverse reinforcing steel bar rolls are sequentially straightened and cut, and a plurality of target longitudinal reinforcing steel bars and a plurality of target transverse reinforcing steel bars are obtained; longitudinal material distribution parameters of all target longitudinal steel bars are obtained for primary judgment, secondary material distribution operation is determined to be started, or a corresponding type of feedback signals are sent out according to the primary judgment result; on the basis of starting a secondary material distribution operation, operating a transportable workbench to enable each target longitudinal steel bar to move, and on the basis that any target longitudinal steel bar reaches a welding position, performing secondary material distribution on the target transverse steel bars on the target longitudinal steel bars in a crossed manner; transverse material distribution parameters are obtained for secondary judgment so as to determine to start cross point welding operation, or a corresponding second-class feedback signal is sent out according to a secondary judgment result; and welding is conducted based on the intersection point welding operation, so that the target prestress positioning mesh is obtained.

Description

Technical Field

[0001] The invention relates to the technical field of steel mesh production, and in particular to a method for producing a universal flexible integrated prestressed positioning mesh. Background Art

[0002] At present, the traditional production of prestressed positioning mesh cannot ensure the stable quality of prestressed positioning mesh, and cannot monitor and feedback in real time and make corresponding adjustments, which increases the chance of errors.

[0003] Chinese patent application publication number CN117696792A discloses a steel mesh production line, including: a welding unit, including a welding seat and a welding device, the welding seat has a welding position, the welding device is arranged on the welding seat corresponding to the welding position, and the welding end of the welding device has a welding state of moving close to the welding position and welding steel bars, and a waiting state of moving away from the welding position and waiting for welding; a longitudinal reinforcement processing unit, including a longitudinal reinforcement conveying device, the longitudinal reinforcement conveying device is suitable for simultaneously conveying multiple longitudinal reinforcements into the welding position; a transverse reinforcement processing unit, including a transverse reinforcement feeding device, the transverse reinforcement feeding port of the transverse reinforcement feeding device is arranged corresponding to the welding position, and the transverse reinforcement feeding device is suitable for dropping the transverse reinforcement onto the multiple longitudinal reinforcements at the welding position.

[0004] It can be seen that the current production of prestressed positioning mesh cannot monitor the production process in real time to provide timely feedback and make corresponding adjustments. Summary of the invention

[0005] To this end, the purpose of the present invention is to provide a universal flexible integrated prestressed positioning mesh production method to overcome the problem that the current prestressed positioning mesh production cannot monitor the production process in real time to provide timely feedback to make corresponding adjustments.

[0006] To achieve the above object, the present invention provides a general-purpose flexible integrated prestressed positioning mesh production method, comprising:

[0007] The longitudinal steel bar coils are straightened and cut in sequence to obtain a number of target longitudinal steel bars;

[0008] The transverse steel bar coils are sequentially straightened and cut to obtain a number of target transverse steel bars;

[0009] Placing each target longitudinal steel bar once on a conveyable workbench according to a longitudinal fixed spacing, obtaining longitudinal distribution parameters, and performing a primary determination based on the longitudinal distribution parameters to determine whether to start a secondary distribution operation, or issuing a corresponding type of feedback signal based on the primary determination result;

[0010] Based on starting the secondary material distribution operation, operating the conveyable workbench to move each target longitudinal steel bar, and based on any target longitudinal steel bar reaching the welding position, placing the target transverse steel bar crosswise on the target longitudinal steel bar for secondary material distribution;

[0011] Acquiring transverse material distribution parameters, performing secondary determination according to the transverse material distribution parameters to determine whether to start the intersection welding operation, or issuing corresponding second-type feedback signals according to the secondary determination results;

[0012] Welding is performed based on the intersection welding operation to obtain a target prestressed positioning mesh.

[0013] Furthermore, the process of performing a primary determination according to the longitudinal cloth parameters to determine whether to start a secondary cloth operation, or issuing a corresponding type of feedback signal according to the primary determination result includes:

[0014] According to the one-time laying result, obtain the actual longitudinal spacings of several single points between any pair of adjacent target longitudinal steel bars, and determine whether the one-time laying of the pair of adjacent target longitudinal steel bars is qualified according to the actual longitudinal spacings of each single point;

[0015] Based on the qualified one-time laying of the single pair of lengths, the point longitudinal spacing difference between the actual longitudinal spacings of each single point is calculated, and for the longitudinal spacing difference of each point, it is determined whether the pair of adjacent target longitudinal steel bars is qualified one-time laying of the single pair of positions according to the longitudinal spacing difference of each point and the preset spacing evaluation value;

[0016] Based on the qualified material distribution of the single pair of positions at one time, the actual longitudinal spacing of the single bars between the remaining target longitudinal steel bars is obtained, and the longitudinal spacing difference between the actual longitudinal spacings of the single bars is calculated;

[0017] For each longitudinal spacing difference, determine whether each target longitudinal steel bar is qualified for one-time placement according to each longitudinal spacing difference and the spacing evaluation value;

[0018] The longitudinal fabric parameters include: the actual longitudinal spacing of each single point and the actual longitudinal spacing of each single root.

[0019] Furthermore, the process of determining whether the pair of adjacent target longitudinal steel bars is qualified for one-time laying of a single pair of lengths according to the actual longitudinal spacing of each single point includes:

[0020] Obtaining the actual longitudinal spacing of each single point of a number of monitoring points between any pair of adjacent target longitudinal steel bars;

[0021] For the actual longitudinal spacing of a single point at any monitoring point, determining whether the monitoring point is qualified according to the actual longitudinal spacing of the single point and the longitudinal fixed spacing;

[0022] Based on the fact that all monitoring points are qualified, it is determined that the single pair of lengths of the adjacent target longitudinal steel bars are qualified for one-time laying.

[0023] Further, for the single-point actual longitudinal spacing of any monitoring point, a first absolute value of a difference between the single-point actual longitudinal spacing and the longitudinal fixed spacing is calculated;

[0024] Whether the monitoring point is qualified is determined according to the first difference absolute value combined with a preset spacing evaluation value; wherein, if the first difference absolute value is less than or equal to the spacing evaluation value, the monitoring point is determined to be qualified; if the first difference absolute value is greater than the spacing evaluation value, the monitoring point is determined to be unqualified; and based on the existence of any unqualified monitoring point among the monitoring points, the single pair of lengths of the pair of adjacent target longitudinal steel bars is determined to be unqualified for one-time laying.

[0025] Further, the process of determining whether the pair of adjacent target longitudinal steel bars is qualified for one-time placement at a single position according to the longitudinal spacing difference of each point and the preset spacing evaluation value includes:

[0026] Get the number of unqualified single point positions in the longitudinal spacing difference of each point;

[0027] Determine whether the pair of adjacent target longitudinal steel bars is qualified for one-time laying at a single position according to the number of unqualified single-point positions;

[0028] Obtain the number of unqualified single roots in the longitudinal spacing difference of each root;

[0029] Whether all target longitudinal steel bars are qualified for one-time laying as a whole is determined according to the number of unqualified single bars.

[0030] Furthermore, the process of performing a primary determination according to the longitudinal cloth parameters to determine whether to start a secondary cloth operation, or issuing a corresponding type of feedback signal according to the primary determination result, further includes:

[0031] Based on determining that the overall first-time material distribution of each target longitudinal steel bar is qualified, starting the second-time material distribution operation;

[0032] Based on the one-time determination result that a single pair of lengths is unqualified, a feedback signal is issued as follows: [actual one-time cloth operation is abnormal];

[0033] When the material distribution at a single pair of positions fails to meet the standard, the feedback signal is determined as [abnormal actual material distribution operation] or [abnormal actual longitudinal steel bar coil straightening] according to the abnormal change trend of the longitudinal spacing difference of each point;

[0034] Based on the overall failure of the first-time laying, the first type of feedback signal is determined as [abnormality in actual first-time laying operation] or [abnormality in actual longitudinal steel bar coil straightening] according to the number of single unqualified bars.

[0035] Further, the process of determining the feedback signal as [actual primary material laying operation abnormality] or [actual longitudinal steel bar coil straightening abnormality] according to the abnormal change trend of the longitudinal spacing difference of each point includes:

[0036] The actual longitudinal spacing of each monitoring point is sequentially obtained in the same direction, and the abnormal change trend is determined to be a linear change trend or a fluctuating change trend according to the numerical change of the actual longitudinal spacing of each single point;

[0037] Based on the abnormal change trend being a linear change trend, determining that the first type of feedback signal is [actual one cloth operation abnormality];

[0038] Based on the fact that the abnormal change trend is a fluctuating change trend, it is determined that the first type of feedback signal is [actual longitudinal steel bar coil straightening abnormality].

[0039] Further, the process of determining the type of feedback signal as [actual primary material laying operation abnormality] or [actual longitudinal steel bar coil straightening abnormality] according to the number of single unqualified bars based on the overall primary material laying being unqualified includes:

[0040] Based on the number of unqualified single threads being 1, it is determined that the first type of feedback signal is [actual one-time cloth operation abnormality];

[0041] Based on the fact that the number of unqualified single bars is greater than 1, it is determined that the first type of feedback signal is [actual longitudinal steel bar coil straightening abnormality].

[0042] Further, the process of performing a secondary determination based on the transverse fabric parameters to determine whether to start the intersection welding operation, or issuing a corresponding second-type feedback signal based on the secondary determination result includes:

[0043] According to the secondary material placement results, the actual layout images of the target transverse reinforcement and the target longitudinal reinforcement are obtained;

[0044] Marking the intersection positions of the target transverse reinforcement and each target longitudinal reinforcement according to the actual layout image, and extracting each intersection center line corresponding to each intersection position;

[0045] Fit each intersection center line, and determine whether to start the intersection welding operation based on the actual fitting results.

[0046] Furthermore, the process of determining whether to start the intersection welding operation according to the actual fitting result includes:

[0047] For any intersection center line, determine the actual fitting angle of the intersection center line, and determine whether the intersection position is qualified for single-point secondary placement according to the actual fitting angle;

[0048] The number of unqualified angles in each intersection position is obtained, and the intersection welding operation is started according to the number of unqualified angles, or the second type of feedback signal is determined to be [actual secondary material distribution operation abnormality], or [actual transverse steel bar coil straightening abnormality].

[0049] Compared with the prior art, the beneficial effect of the present invention lies in that the production speed of prestressed positioning mesh is significantly improved through the automated process, the manual operation time is reduced, and thus the overall production efficiency is improved. The automated process can accurately control the length, spacing and welding quality of the steel bars, reduce human errors, and ensure the consistency and quality of the prestressed positioning mesh. Automation reduces the direct contact between workers and mechanical operations, reduces the risk of work-related injuries, and improves the safety of the working environment. The application of image acquisition technology enables every link in the production process to be monitored in real time. Once a problem is found, a feedback signal can be immediately issued to facilitate timely adjustment and correction. The laying position of the steel bars can be accurately controlled to ensure the accuracy of the mesh. Through the refined automated process, not only the production efficiency and product quality are improved, but also the controllability and safety of the production process are enhanced.

[0050] By monitoring and evaluating the actual longitudinal spacing of a single point, it is possible to ensure that the length between each pair of adjacent target longitudinal reinforcements is qualified, thereby ensuring the accuracy and quality of the entire prestressed positioning mesh. The calculation of the point longitudinal spacing difference and the root longitudinal spacing difference helps to ensure that the position of each reinforcement in the prestressed positioning mesh is uniform and consistent, avoiding structural weaknesses caused by uneven material distribution. The real-time judgment and feedback signal mechanism can quickly identify and respond to any deviations in the material distribution process, so as to make timely adjustments. Through detailed analysis of the material distribution parameters, it can ensure that only qualified products can enter the next production stage, thereby improving the overall quality of the final product. By analyzing the abnormal change trend of the spacing difference , can distinguish whether the error is caused by abnormal material operation or abnormal straightening of the steel bar coil, which helps to quickly locate the source of the problem. The automated judgment process reduces the need for manual inspection, speeds up production, and improves production efficiency. Through continuous monitoring of the production process, it helps to maintain a safe working environment and reduce safety risks caused by equipment failure or operating errors. It records the judgment results and feedback signals of each step, and provides valuable data support for subsequent quality control and production improvements. The implementation of a one-time judgment process has brought a higher level of automation, better quality control, faster fault response and higher production efficiency to the production of prestressed positioning mesh.

[0051] By acquiring the actual layout image and marking the intersection position, the intersection of the transverse and longitudinal steel bars can be accurately identified, providing accurate position information for the welding operation. By fitting the intersection centerline and determining the actual fitting angle, the accuracy of the intersection welding is ensured, thereby improving the welding quality. The automatic determination of whether to start the intersection welding operation reduces manual judgment and operation, improves production efficiency, monitors the quality of the material distribution at the intersection in real time, and quickly responds to any deviation through the second-class feedback signal, allowing timely adjustments to avoid production delays. By ensuring that all intersections are properly distributed before welding, the process reduces rework and material waste caused by improper distribution. By analyzing the number of unqualified angles, the process can distinguish different types of abnormalities, such as abnormal straightening of the transverse steel bar coil or abnormal secondary distribution operation, which helps to solve the problem in a targeted manner. Accurate intersection welding reduces structural weaknesses caused by improper welding, improves the safety and reliability of the final product, ensures that the material distribution and welding quality of all intersections are consistent, and improves the uniformity and consistency of the entire prestressed positioning mesh product. The implementation of the secondary determination process brings accurate welding preparation, efficient automation control, real-time quality monitoring and effective fault diagnosis to the production of prestressed positioning mesh. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 It is a flow chart of a method for producing a universal flexible integrated prestressed positioning mesh according to an embodiment of the present invention;

[0053] Figure 2 This is a primary determination flow chart in a method for producing a universal flexible integrated prestressed positioning mesh according to an embodiment of the present invention;

[0054] Figure 3 A flow chart of determining a type of feedback signal in a method for producing a universal flexible integrated prestressed positioning mesh according to an embodiment of the present invention;

[0055] Figure 4 This is a secondary determination flow chart in the method for producing a universal flexible integrated prestressed positioning mesh according to an embodiment of the present invention. DETAILED DESCRIPTION

[0056] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0057] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the protection scope of the present invention.

[0058] It should be noted that, in the description of the present invention, terms such as "up", "down", "left", "right", "inside" and "outside" indicating directions or positional relationships are based on the directions or positional relationships shown in the drawings. This is merely for the convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it cannot be understood as a limitation on the present invention.

[0059] See also Figure 1 As shown, the present invention provides a general flexible integrated prestressed positioning mesh production method, comprising:

[0060] Step S100, straightening and cutting the longitudinal steel bar coil in sequence to obtain a plurality of target longitudinal steel bars;

[0061] Step S200, straightening and cutting the transverse steel bar coil in sequence to obtain a plurality of target transverse steel bars;

[0062] Step S300, placing each target longitudinal steel bar once on a conveyable workbench according to a longitudinal fixed spacing, obtaining longitudinal laying parameters, and performing a primary determination based on the longitudinal laying parameters to determine whether to start a secondary laying operation, or issuing a corresponding type of feedback signal based on the primary determination result;

[0063] Step S400, based on starting the secondary material distribution operation, operating the conveyable workbench to move each target longitudinal steel bar, and based on any target longitudinal steel bar reaching the welding position, placing the target transverse steel bar crosswise on the target longitudinal steel bar for secondary material distribution;

[0064] Step S500, obtaining transverse material distribution parameters, performing secondary determination according to the transverse material distribution parameters to determine whether to start the intersection welding operation, or issuing corresponding second-type feedback signals according to the secondary determination results;

[0065] Step S600, welding is performed based on the intersection welding operation to obtain a target prestressed positioning mesh.

[0066] In this embodiment, the longitudinal steel bar coil is placed on a straightening machine for straightening. During the straightening process, the longitudinal steel bar passes through a series of straightening wheels to eliminate its internal stress and meet the linearity requirement. The straightened longitudinal steel bar is fed into a cutting machine, and the cutting machine automatically cuts according to the preset length parameters. For example, in the specific implementation process, the preset length of the target longitudinal steel bar is 6000mm and the diameter is 12mm; wherein, the straightening wheel spacing and pressure of the straightening machine are adjusted according to the steel bar diameter to ensure the straightening effect, and the cutting machine is set to cut out 6000mm long steel bars each time; in this embodiment, the straightening and cutting process of the transverse steel bar coil is consistent with the straightening and cutting process of the longitudinal steel bar coil, for example, the preset target transverse steel bar length is 3000mm and the diameter is 10mm, that is, the cutting machine is set to cut out 3000mm long target transverse steel bars each time; wherein, the setting of the longitudinal fixed spacing is affected by the design requirements and the specifications of the prestressed positioning mesh; in actual applications, the conveyable workbench is part of an automated conveyor line, such as a chain conveyor belt, a roller conveyor belt or a pneumatic conveying system, which is not specifically limited in this embodiment.

[0067] Specifically, for example, the longitudinal steel bar coil is straightened and cut to obtain a 6000 mm long longitudinal steel bar, and the transverse steel bar coil is straightened and cut to obtain a 3000 mm long transverse steel bar. The straightened and cut longitudinal steel bars are laid on the chain conveyor belt at a spacing of 200 mm, and the longitudinal laying parameters are obtained through image acquisition technology to make a judgment to determine whether to start the secondary laying operation. Based on the start of the secondary laying operation, the conveyor belt moves the longitudinal steel bars. When it reaches the welding position, the secondary laying of the transverse steel bars is carried out. The transverse steel bars cross the longitudinal steel bars. The transverse laying parameters are obtained through image acquisition technology, and a secondary judgment is made to determine whether to start the intersection welding operation. Based on the completion of all welding operations, the target prestressed positioning mesh is obtained.

[0068] In this embodiment, the intersection points of the transverse steel bars and the longitudinal steel bars are welded together by spot welding or other welding methods to form a mesh structure. The specific welding method is not specifically limited in this embodiment. The image acquisition technology refers to capturing the position and state of the steel bars by using various sensors and cameras, such as a high-resolution camera or a laser scanner, which is not specifically limited in this embodiment.

[0069] Specifically, the embodiments of the present invention significantly improve the production speed of prestressed positioning meshes through automated processes, reduce manual operation time, and thus improve overall production efficiency. The automated process can accurately control the length, spacing, and welding quality of the steel bars, reduce human errors, and ensure the consistency and quality of the prestressed positioning meshes. Automation reduces direct contact between workers and mechanical operations, reduces the risk of work-related injuries, and improves the safety of the working environment. The application of image acquisition technology enables every link in the production process to be monitored in real time. Once a problem is found, a feedback signal can be immediately issued to facilitate timely adjustment and correction. The laying position of the steel bars can be accurately controlled to ensure the accuracy of the mesh. Through a refined automated process, not only the production efficiency and product quality are improved, but also the controllability and safety of the production process are enhanced.

[0070] See also Figure 2 As shown, it is a primary determination flow chart, wherein the process of performing a primary determination according to the longitudinal cloth parameters to determine whether to start a secondary cloth operation, or issuing a corresponding type of feedback signal according to the primary determination result includes:

[0071] Step S310, obtaining a plurality of single-point actual longitudinal spacings between any pair of adjacent target longitudinal steel bars according to the one-time laying result, and determining whether the pair of adjacent target longitudinal steel bars is qualified for one-time laying according to the single-point actual longitudinal spacings;

[0072] Step S320, based on the qualified one-time laying of the single pair of lengths, the point longitudinal spacing difference between the actual longitudinal spacings of each single point is calculated, and for the longitudinal spacing difference of each point, it is determined whether the pair of adjacent target longitudinal steel bars are qualified for one-time laying of the single pair of positions according to the longitudinal spacing difference of each point and a preset spacing evaluation value;

[0073] Step S330, based on the qualified material distribution at the single pair of positions, obtaining the actual longitudinal spacing between the remaining target longitudinal steel bars, and calculating the longitudinal spacing difference between the actual longitudinal spacings;

[0074] Step S340, for each longitudinal spacing difference, determine whether each target longitudinal steel bar is qualified for one-time laying according to each longitudinal spacing difference and the spacing evaluation value;

[0075] The longitudinal fabric parameters include: the actual longitudinal spacing of each single point and the actual longitudinal spacing of each single root.

[0076] Specifically, the process of determining whether the pair of adjacent target longitudinal steel bars is qualified for one-time laying of a single pair of lengths according to the actual longitudinal spacing of each single point in this embodiment includes:

[0077] Step S311, obtaining the actual longitudinal spacing of each single point of a plurality of monitoring points between any pair of adjacent target longitudinal steel bars;

[0078] Step S312, for the actual single-point longitudinal spacing of any monitoring point, determine whether the monitoring point is qualified according to the actual single-point longitudinal spacing and the longitudinal fixed spacing;

[0079] Step S313: based on the fact that all monitoring points are qualified, it is determined that the single pair of lengths of the adjacent target longitudinal steel bars are qualified for one-time laying.

[0080] In this embodiment, for the single-point actual longitudinal spacing of any monitoring point, a first absolute value of a difference between the single-point actual longitudinal spacing and the longitudinal fixed spacing is calculated;

[0081] The absolute value of the first difference = |actual vertical spacing of a single point - fixed vertical spacing|;

[0082] Whether the monitoring point is qualified is determined according to the first absolute value of the difference in combination with a preset spacing evaluation value; if the first absolute value of the difference is less than or equal to the spacing evaluation value, the monitoring point is determined to be qualified; if the first absolute value of the difference is greater than the spacing evaluation value, the monitoring point is determined to be unqualified; and based on the existence of any unqualified monitoring point among the monitoring points, the single pair of lengths of the pair of adjacent target longitudinal steel bars is determined to be unqualified for one-time laying.

[0083] Specifically, the process of determining whether the pair of adjacent target longitudinal steel bars is qualified for one-time placement at a single position according to the longitudinal spacing difference of each point and the preset spacing evaluation value in this embodiment includes:

[0084] Step S321, obtaining the number of unqualified single point positions in the longitudinal spacing difference of each point;

[0085] Step S322, determining whether the pair of adjacent target longitudinal steel bars is qualified for one-time laying at a single position according to the number of unqualified single-point positions;

[0086] Among them, based on the fact that the number of unqualified single-point positions is 0, it is determined that the one-time laying of the pair of adjacent target longitudinal steel bars is qualified; based on the fact that the number of unqualified single-point positions is not 0, it is determined that the one-time laying of the pair of adjacent target longitudinal steel bars is unqualified.

[0087] During the specific implementation process, for the longitudinal spacing difference of any point, if the longitudinal spacing difference of the point is less than or equal to the spacing evaluation value, the longitudinal spacing difference of the point is judged to be qualified; if the longitudinal spacing difference of the point is greater than the spacing evaluation value, the longitudinal spacing difference of the point is judged to be unqualified; the number of unqualified point longitudinal spacing differences is recorded, that is, the number of unqualified single point positions is obtained.

[0088] Specifically, in this embodiment, the process of determining whether each target longitudinal steel bar is qualified for one-time laying as a whole according to the longitudinal spacing difference of each steel bar and the spacing evaluation value includes:

[0089] Step S341, obtaining the number of unqualified single roots in the longitudinal spacing difference of each root;

[0090] Step S342, determining whether all target longitudinal steel bars are qualified for one-time laying according to the number of unqualified single bars;

[0091] Among them, based on the fact that the number of unqualified single bars is 0, it is determined that the overall one-time laying of each target longitudinal steel bar is qualified; based on the fact that the number of unqualified single bars is not 0, it is determined that the overall one-time laying of each target longitudinal steel bar is unqualified.

[0092] During the specific implementation process, for any root longitudinal spacing difference, if the root longitudinal spacing difference is less than or equal to the spacing evaluation value, the root longitudinal spacing difference is judged to be qualified; if the root longitudinal spacing difference is greater than the spacing evaluation value, the root longitudinal spacing difference is judged to be unqualified; the number of unqualified root longitudinal spacing differences is recorded, that is, the number of single unqualified root longitudinal spacing differences is obtained.

[0093] Specifically, the process of performing a primary determination according to the longitudinal cloth parameters in this embodiment to determine to start a secondary cloth operation, or issuing a corresponding type of feedback signal according to the primary determination result, further includes:

[0094] Step S350, based on determining that the overall first-time material distribution of each target longitudinal steel bar is qualified, the second-time material distribution operation is started;

[0095] Step S360, based on the one-time determination result that the single pair of lengths is unqualified, a feedback signal of type: [actual one-time cloth operation is abnormal] is issued;

[0096] Step S370, when the first material distribution at a single pair of positions is unqualified, the first type of feedback signal is determined as [actual first material distribution operation is abnormal] or [actual longitudinal steel bar coil straightening is abnormal] according to the abnormal change trend of the longitudinal spacing difference of each point;

[0097] Step S380, based on the overall first-time material distribution being unqualified, the first-type feedback signal is determined as [actual first-time material distribution operation is abnormal] or [actual longitudinal steel bar coil straightening is abnormal] according to the number of unqualified single bars.

[0098] See also Figure 3 As shown, it is a flow chart for determining a type of feedback signal, wherein the process of determining the type of feedback signal as [actual primary material laying operation abnormality] or [actual longitudinal steel bar coil straightening abnormality] according to the abnormal change trend of the longitudinal spacing difference of each point includes:

[0099] Step S371, sequentially obtaining the actual longitudinal spacing of each monitoring point in the same direction, and determining whether the abnormal change trend is a linear change trend or a fluctuating change trend according to the numerical change of the actual longitudinal spacing of each single point;

[0100] Step S372, based on the abnormal change trend being a linear change trend, determining that the first type of feedback signal is [actual one cloth operation abnormality];

[0101] Step S373, based on the abnormal change trend being a fluctuating change trend, determining that the first type of feedback signal is [actual longitudinal steel bar coil straightening abnormality].

[0102] Specifically, the process of determining the feedback signal as [actual primary material distribution operation abnormality] or [actual longitudinal steel bar coil straightening abnormality] based on the overall primary material distribution failure and the number of single unqualified steel bars in this embodiment includes:

[0103] Step S381, based on the number of unqualified single yarns being 1, determining that the first type of feedback signal is [actual one cloth laying operation is abnormal];

[0104] Step S382: based on the fact that the number of unqualified single bars is greater than 1, it is determined that the first type of feedback signal is [actual longitudinal steel bar coil straightening abnormality].

[0105] Specifically, the embodiment of the present invention can ensure that the length between each pair of adjacent target longitudinal steel bars is qualified by monitoring and evaluating the actual longitudinal spacing of a single point, thereby ensuring the accuracy and quality of the entire prestressed positioning mesh. The calculation point longitudinal spacing difference and the root longitudinal spacing difference help to ensure that the position of each steel bar in the prestressed positioning mesh is uniform and consistent, avoiding structural weaknesses caused by uneven distribution. The real-time judgment and feedback signal mechanism can quickly identify and respond to any deviations in the distribution process, so as to make timely adjustments. Through detailed analysis of the distribution parameters, it can ensure that only qualified products can enter the next production stage, thereby improving the overall quality of the final product. By analyzing the spacing difference The abnormal change trend can distinguish whether the error is caused by abnormal material operation or abnormal straightening of the steel bar coil, which helps to quickly locate the source of the problem. The automated judgment process reduces the need for manual inspection, speeds up production, and improves production efficiency. Through continuous monitoring of the production process, it helps to maintain a safe working environment and reduce safety risks caused by equipment failure or operating errors. Recording the judgment results and feedback signals of each step provides valuable data support for subsequent quality control and production improvements. The implementation of a one-time judgment process has brought a higher level of automation, better quality control, faster fault response and higher production efficiency to the production of prestressed positioning mesh.

[0106] See also Figure 4 As shown, it is a secondary determination flow chart, wherein the process of performing secondary determination according to the transverse fabric parameters to determine to start the intersection welding operation, or issuing corresponding second-type feedback signals according to the secondary determination results includes:

[0107] Step S510, obtaining an actual layout image of the target transverse reinforcement and the target longitudinal reinforcement according to the secondary material placement result;

[0108] Step S520, marking the intersection positions of the target transverse reinforcement and each target longitudinal reinforcement according to the actual layout image, and extracting each intersection center line corresponding to each intersection position;

[0109] Step S530, fitting each intersection center line, and determining whether to start the intersection welding operation according to the actual fitting result.

[0110] Specifically, the process of determining whether to start the intersection welding operation according to the actual fitting result in this embodiment includes:

[0111] Step S531, for any intersection center line, determine the actual fitting angle of the intersection center line, and determine whether the intersection position is qualified for single-point secondary fabrication according to the actual fitting angle;

[0112] Step S532, obtaining the number of unqualified angles in each intersection position, and determining to start the intersection welding operation according to the number of unqualified angles, or determining that the second type of feedback signal is [actual secondary material distribution operation abnormality], or [actual transverse steel bar coil straightening abnormality].

[0113] In this embodiment, the actual arrangement image is acquired by using various sensors and cameras, and the image acquisition device should be installed perpendicular to the monitored surface to ensure that the proportion and angle relationship of the actual arrangement image are accurate to avoid measurement errors caused by angle deviation;

[0114] In the specific implementation process, for any actual fitting angle, it is determined whether the actual fitting angle is within the error range allowed by the actual project. If so, it is considered that the single-point secondary distribution at the intersection is qualified; for any actual fitting angle that is not within the error range allowed by the actual project, the single-point secondary distribution at the intersection is unqualified; the number of intersections where the single-point secondary distribution is unqualified is recorded, that is, the number of unqualified angles is obtained; based on the number of unqualified angles being 0, it is determined to start the intersection welding operation; based on the number of unqualified angles being 1, it is determined that the second type of feedback signal is [actual transverse steel bar coil straightening abnormality]; based on the number of unqualified angles being greater than 1, it is determined that the second type of feedback signal is [actual secondary distribution operation abnormality].

[0115] Specifically, the embodiment of the present invention can accurately identify the intersection of the transverse steel bar and the longitudinal steel bar by acquiring the actual layout image and marking the intersection position, provide accurate position information for the welding operation, and ensure the accuracy of the intersection welding by fitting the intersection center line and determining the actual fitting angle, thereby improving the welding quality. It automatically determines whether to start the intersection welding operation, reduces manual judgment and operation, improves production efficiency, monitors the quality of the material distribution at the intersection in real time, and quickly responds to any deviation through the second type of feedback signal, allowing timely adjustment to avoid production delays. By ensuring that all intersections are qualified before welding, the process reduces rework and material waste caused by improper material distribution. By analyzing the number of unqualified angles, the process can distinguish different types of abnormalities, such as abnormal straightening of the transverse steel bar coil or abnormal secondary material distribution operation, which helps to solve the problem in a targeted manner. Accurate intersection welding reduces structural weaknesses caused by improper welding, improves the safety and reliability of the final product, ensures that the material distribution and welding quality of all intersections are consistent, and improves the uniformity and consistency of the entire prestressed positioning mesh product. The implementation of the secondary determination process brings accurate welding preparation, efficient automation control, real-time quality monitoring and effective fault diagnosis to the production of prestressed positioning mesh.

[0116] The calculation compensation parameters and the calculation adjustment parameters described in the present invention have two functions: one is to balance the left and right dimensions of the formula, and the other is to adjust the numerical results. No specific assignment is performed in this embodiment. In addition, the calculation formulas in this embodiment are used to intuitively reflect the adjustment relationship between the numerical values, such as positive correlation and negative correlation. Unless otherwise specified, the parameter values ​​that are not specifically limited to numerical values ​​are all positive.

[0117] So far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easy for those skilled in the art to understand that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will fall within the protection scope of the present invention.

[0118] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. For those skilled in the art, the present invention may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A method for producing a universal flexible integrated prestressed positioning mesh, comprising: The longitudinal steel bar coils are straightened and cut in sequence to obtain a number of target longitudinal steel bars; The transverse steel bar coils are sequentially straightened and cut to obtain a number of target transverse steel bars; Placing each target longitudinal steel bar once on a conveyable workbench according to a longitudinal fixed spacing, obtaining longitudinal distribution parameters, and performing a primary determination based on the longitudinal distribution parameters to determine whether to start a secondary distribution operation, or issuing a corresponding type of feedback signal based on the primary determination result; Based on starting the secondary material distribution operation, operating the conveyable workbench to move each target longitudinal steel bar, and based on any target longitudinal steel bar reaching the welding position, placing the target transverse steel bar crosswise on the target longitudinal steel bar for secondary material distribution; Acquiring transverse material distribution parameters, performing secondary determination according to the transverse material distribution parameters to determine whether to start the intersection welding operation, or issuing corresponding second-type feedback signals according to the secondary determination results; Welding is performed based on the intersection welding operation to obtain a target prestressed positioning mesh.

2. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 1, characterized in that: The process of performing a primary determination according to the longitudinal cloth parameters to determine to start a secondary cloth operation, or issuing a corresponding type of feedback signal according to the primary determination result includes: According to the one-time laying result, obtain the actual longitudinal spacings of several single points between any pair of adjacent target longitudinal steel bars, and determine whether the one-time laying of the pair of adjacent target longitudinal steel bars is qualified according to the actual longitudinal spacings of each single point; Based on the qualified one-time laying of the single pair of lengths, the point longitudinal spacing difference between the actual longitudinal spacings of each single point is calculated, and for the longitudinal spacing difference of each point, it is determined whether the pair of adjacent target longitudinal steel bars is qualified one-time laying of the single pair of positions according to the longitudinal spacing difference of each point and the preset spacing evaluation value; Based on the qualified material distribution of the single pair of positions at one time, the actual longitudinal spacing of the single bars between the remaining target longitudinal steel bars is obtained, and the longitudinal spacing difference between the actual longitudinal spacings of the single bars is calculated; For each longitudinal spacing difference, determine whether each target longitudinal steel bar is qualified for one-time placement according to each longitudinal spacing difference and the spacing evaluation value; The longitudinal fabric parameters include: the actual longitudinal spacing of each single point and the actual longitudinal spacing of each single root.

3. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 2, characterized in that: The process of determining whether the pair of adjacent target longitudinal steel bars is qualified for one-time laying of the length of the pair of adjacent target steel bars according to the actual longitudinal spacing of each single point includes: Obtaining the actual longitudinal spacing of each single point of a number of monitoring points between any pair of adjacent target longitudinal steel bars; For the actual longitudinal spacing of a single point at any monitoring point, determining whether the monitoring point is qualified according to the actual longitudinal spacing of the single point and the longitudinal fixed spacing; Based on the fact that all monitoring points are qualified, it is determined that the single pair of lengths of the adjacent target longitudinal steel bars are qualified for one-time laying.

4. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 3, characterized in that: For the single-point actual longitudinal spacing of any monitoring point, calculate the first absolute value of the difference between the single-point actual longitudinal spacing and the longitudinal fixed spacing; Determine whether the monitoring point is qualified according to the first absolute value of the difference and a preset spacing evaluation value; wherein, if the first absolute value of the difference is less than or equal to the spacing evaluation value, the monitoring point is determined to be qualified; If the absolute value of the first difference is greater than the spacing evaluation value, the monitoring point is determined to be unqualified; and based on the existence of any unqualified monitoring point among the monitoring points, the single pair of lengths of the pair of adjacent target longitudinal steel bars is determined to be unqualified for one-time laying.

5. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 4, characterized in that: The process of determining whether the pair of adjacent target longitudinal steel bars is qualified for one-time placement at a single position according to the longitudinal spacing difference of each point and the preset spacing evaluation value comprises: Get the number of unqualified single point positions in the longitudinal spacing difference of each point; Determine whether the pair of adjacent target longitudinal steel bars is qualified for one-time laying at a single position according to the number of unqualified single-point positions; Obtain the number of unqualified single roots in the longitudinal spacing difference of each root; Whether all target longitudinal steel bars are qualified for one-time laying as a whole is determined according to the number of unqualified single bars.

6. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 5, characterized in that: The process of performing a primary determination according to the longitudinal cloth parameters to determine to start a secondary cloth operation, or issuing a corresponding type of feedback signal according to the primary determination result, further includes: Based on determining that the overall first-time material distribution of each target longitudinal steel bar is qualified, starting the second-time material distribution operation; Based on the one-time determination result that a single pair of lengths is unqualified, a feedback signal is issued as follows: [actual one-time cloth operation is abnormal]; When the material distribution at a single pair of positions fails to meet the standard, the feedback signal is determined as [abnormal actual material distribution operation] or [abnormal actual longitudinal steel bar coil straightening] according to the abnormal change trend of the longitudinal spacing difference of each point; Based on the overall failure of the first-time laying, the first type of feedback signal is determined as [abnormality in actual first-time laying operation] or [abnormality in actual longitudinal steel bar coil straightening] according to the number of single unqualified bars.

7. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 6, characterized in that: The process of determining the feedback signal as [actual abnormality in a material laying operation] or [actual abnormality in the straightening of the longitudinal steel bar coil] according to the abnormal change trend of the longitudinal spacing difference of each point includes: The actual longitudinal spacing of each monitoring point is sequentially obtained in the same direction, and the abnormal change trend is determined to be a linear change trend or a fluctuating change trend according to the numerical change of the actual longitudinal spacing of each single point; Based on the abnormal change trend being a linear change trend, determining that the first type of feedback signal is [actual one cloth operation abnormality]; Based on the fact that the abnormal change trend is a fluctuating change trend, it is determined that the first type of feedback signal is [actual longitudinal steel bar coil straightening abnormality].

8. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 7, characterized in that: The process of determining the first type of feedback signal as [actual first time material laying operation abnormality] or [actual longitudinal steel bar coil straightening abnormality] based on the overall first time material laying failure and the number of single failed steel bars comprises: Based on the number of unqualified single threads being 1, it is determined that the first type of feedback signal is [actual one-time cloth operation abnormality]; Based on the fact that the number of unqualified single bars is greater than 1, it is determined that the first type of feedback signal is [actual longitudinal steel bar coil straightening abnormality].

9. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 8, characterized in that: The process of performing secondary determination according to the transverse material distribution parameters to determine to start the intersection welding operation, or issuing corresponding second-type feedback signals according to the secondary determination results includes: According to the secondary material placement results, the actual layout images of the target transverse reinforcement and the target longitudinal reinforcement are obtained; Marking the intersection positions of the target transverse reinforcement and each target longitudinal reinforcement according to the actual layout image, and extracting each intersection center line corresponding to each intersection position; Fit each intersection center line, and determine whether to start the intersection welding operation based on the actual fitting results.

10. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 9, characterized in that: The process of determining whether to start the intersection welding operation according to the actual fitting result includes: For any intersection center line, determine the actual fitting angle of the intersection center line, and determine whether the intersection position is qualified for single-point secondary placement according to the actual fitting angle; The number of unqualified angles in each intersection position is obtained, and the intersection welding operation is started according to the number of unqualified angles, or the second type of feedback signal is determined to be [actual secondary material distribution operation abnormality], or [actual transverse steel bar coil straightening abnormality].

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