A general flexible integrated prestressed positioning net production method

Abstract

The present application relates to the technical field of reinforcing mesh production, in particular to a universal flexible integrated prestressed positioning mesh production method, which comprises the following steps: sequentially straightening and cutting longitudinal steel reinforcement coils and transverse steel reinforcement coils to obtain a plurality of target longitudinal steel reinforcements and a plurality of target transverse steel reinforcements; obtaining longitudinal distribution parameters of each target longitudinal steel reinforcement to make a first determination, determining to start a secondary distribution operation, or issuing a corresponding first feedback signal according to the first determination result; based on the secondary distribution operation, operating a conveying workbench to move each target longitudinal steel reinforcement, and based on any target longitudinal steel reinforcement reaching a welding position, the target transverse steel reinforcement is crossly arranged on the target longitudinal steel reinforcement for secondary distribution; obtaining transverse distribution parameters to make a second determination to determine to start a cross point welding operation, or issuing a corresponding second feedback signal according to the second determination result; based on the cross point welding operation, welding is performed to obtain a target prestressed positioning mesh.

Description

Technical Field

[0001] The present invention relates to the technical field of steel mesh production, 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, comprising: a welding unit, comprising a welding seat and a welding device, the welding seat having a welding position, the welding device being arranged on the welding seat corresponding to the welding position, the welding end of the welding device having 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, comprising a longitudinal reinforcement conveying device, the longitudinal reinforcement conveying device being suitable for simultaneously conveying multiple longitudinal reinforcements into the welding position; a transverse reinforcement processing unit, comprising a transverse reinforcement feeding device, the transverse reinforcement feeding port of the transverse reinforcement feeding device being arranged corresponding to the welding position, and the transverse reinforcement feeding device being suitable for dropping the transverse reinforcements onto the multiple longitudinal reinforcements at the welding position.

[0004] This shows 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 straightened and cut in sequence to obtain a number of target transverse steel bars;

[0009] Placing each target longitudinal steel bar on a conveyable workbench at a fixed longitudinal spacing, obtaining longitudinal distribution parameters, and performing a primary determination based on the longitudinal distribution parameters to determine whether to initiate 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 based on the transverse material distribution parameters to determine whether to start the intersection welding operation, or issuing corresponding second-type feedback signals based on 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 based on the longitudinal cloth parameters to determine whether to start a secondary cloth operation, or issuing a corresponding type of feedback signal based on the primary determination result, includes:

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

[0015] Based on the qualified single pair lengths for one-time laying, calculating the point longitudinal spacing difference between the actual longitudinal spacings of each single point, and determining whether the pair of adjacent target longitudinal steel bars are qualified for one-time laying at the single pair position according to the longitudinal spacing difference of each point and a preset spacing evaluation value;

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

[0017] For each longitudinal spacing difference, determine whether each target longitudinal steel bar is qualified for the overall 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 thread.

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

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

[0021] 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;

[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] Furthermore, 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 based on the absolute value of the first difference in combination with a preset spacing evaluation value; wherein, if the absolute value of the first 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.

[0025] Furthermore, 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 at each point and a preset spacing evaluation value includes:

[0026] Obtain 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 are qualified for one-time placement at a single position according to the number of unqualified single-point positions;

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

[0029] Whether the overall one-time laying of each target longitudinal steel bar is qualified is determined based on the number of unqualified single bars.

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

[0031] Based on the determination that the overall first-time placement of each target longitudinal steel bar is qualified, the second-time placement operation is started;

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

[0033] When the first-time laying of a single pair of positions is unqualified, the first type of feedback signal is determined to be [abnormal actual first-time laying 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 batch of material distribution, the first type of feedback signal is determined to be [abnormal actual first batch material distribution operation] or [abnormal actual longitudinal steel bar coil straightening] according to the number of unqualified individual bars.

[0035] Furthermore, the process of determining the feedback signal as "abnormality in actual primary material laying operation" or "abnormality in actual longitudinal steel bar coil straightening" based on the abnormal change trend of the longitudinal spacing difference at each point includes:

[0036] 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 based on 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-time 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] Furthermore, the process of determining the type of feedback signal as [actual primary material laying operation abnormality] or [actual longitudinal steel bar coil straightening abnormality] based on the overall primary material laying failure and the number of unqualified individual bars includes:

[0040] Based on the number of unqualified single pieces being 1, it is determined that the first type of feedback signal is [actual one-time cloth laying 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 [abnormal straightening of the actual longitudinal steel bar coil].

[0042] Furthermore, 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] Obtain the actual layout images of the target transverse reinforcement and the target longitudinal reinforcement according to the secondary placement results;

[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 centerline 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 based on the actual fitting angle;

[0048] Obtain the number of unqualified angles in each intersection position, and determine to start the intersection welding operation based on the number of unqualified angles, or determine that the second type of feedback signal is [actual secondary material distribution operation abnormality] or [actual transverse steel bar coil straightening abnormality].

[0049] Compared with the existing technology, the beneficial effect of the present invention is 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 issued immediately, which is convenient for 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 distribution. The real-time judgment and feedback signal mechanism can quickly identify and respond to any deviations in the distribution process, so that timely adjustments can be made. 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 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. The judgment results and feedback signals of each step are recorded, which 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 capturing images of the actual layout and marking the intersection locations, the system can accurately identify the intersections of transverse and longitudinal rebar, providing accurate location information for welding operations. Fitting the intersection centerline and determining the actual fitting angle ensures accurate intersection welding, thereby improving weld quality. Automatically determining whether to initiate intersection welding reduces manual judgment and operation, improving production efficiency. The system monitors the material placement quality at intersections in real time and quickly responds to any deviations through a secondary feedback signal, allowing for timely adjustments and avoiding production delays. By ensuring that all intersections are properly placed before welding, the process reduces rework and material waste caused by improper placement. By analyzing the number of unqualified angles, the process can distinguish different types of anomalies, such as abnormal transverse rebar coil straightening or secondary placement operations, helping to address them in a targeted manner. Accurate intersection welding reduces structural weaknesses caused by improper welding, improving the safety and reliability of the final product. By ensuring consistent placement and welding quality at all intersections, the system enhances the uniformity and consistency of the entire prestressed positioning mesh product. The implementation of the secondary determination process brings precise weld preparation, efficient automated control, real-time quality monitoring, and effective fault diagnosis to the production of prestressed positioning mesh. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 This 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 flow chart of a primary determination 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 merely used to explain the present invention and are not intended 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 scope of protection 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 accompanying drawings. This is only 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 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 reinforcement bar on a conveyable workbench at a fixed longitudinal spacing, obtaining longitudinal distribution parameters, and performing a primary determination based on the longitudinal distribution parameters to determine whether to initiate a secondary distribution operation, or issuing a corresponding type of feedback signal based on the primary determination result.

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

[0064] Step S500, obtaining transverse material distribution parameters, performing secondary determination based on the transverse material distribution parameters to determine whether to start the intersection welding operation, or issuing corresponding second-type feedback signals based on 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 achieve linearity requirements. The straightened longitudinal steel bar is fed into a cutting machine, which automatically cuts it according to preset length parameters. For example, in a specific implementation, the preset length of the target longitudinal steel bar is 6000 mm and the diameter is 12 mm. The spacing and pressure of the straightening wheels of the straightening machine are adjusted according to the diameter of the steel bar to ensure the straightening effect. The cutting machine is set to cut 6000 mm 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 length of the target transverse steel bar is 3000 mm and the diameter is 10 mm. That is, the cutting machine is set to cut 3000 mm long target transverse steel bars each time. The setting of the longitudinal fixed spacing is affected by 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 6000mm long longitudinal steel bar, and the transverse steel bar coil is straightened and cut to obtain a 3000mm long transverse steel bar. The straightened and cut longitudinal steel bars are laid on the chain conveyor belt at a spacing of 200mm, 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 performed. 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 intersections 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. This embodiment does not specifically limit the specific welding method. The image acquisition technology refers to capturing the position and status of the steel bars by using various sensors and cameras, such as high-resolution cameras or laser scanners. This embodiment does not specifically limit the specific method.

[0069] Specifically, the embodiments of the present invention significantly improve the production speed of prestressed positioning mesh through an automated process, 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 mesh. 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 issued immediately 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.

[0070] See Figure 2 As shown, it is a primary determination flow chart, wherein the process of performing a primary determination based on the longitudinal fabric parameters to determine whether to start a secondary fabric operation, or issuing a corresponding type of feedback signal based on 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 are qualified for one-time laying according to the single-point actual longitudinal spacings;

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

[0073] Step S330: Based on the qualified placement of the single pair of positions, the actual longitudinal spacing between the remaining target longitudinal steel bars is obtained, and the longitudinal spacing difference between the actual longitudinal spacings is calculated;

[0074] Step S340, 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;

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

[0076] Specifically, the process of determining whether the pair of adjacent target longitudinal steel bars is qualified for one-time laying of the length thereof 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 actual single-point longitudinal spacing of any monitoring point, the first absolute value of the difference between the actual single-point longitudinal spacing and the fixed longitudinal 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 based on the absolute value of the first difference in combination with a preset spacing evaluation value; if the absolute value of the first 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.

[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 based on the longitudinal spacing difference at 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 are qualified for one-time laying at a single position based on 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 single pair of adjacent target longitudinal steel bars is qualified for one-time laying; based on the fact that the number of unqualified single-point positions is not 0, it is determined that the single pair of adjacent target longitudinal steel bars is unqualified for one-time laying.

[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 longitudinal spacing differences of the points is recorded, that is, the number of unqualified single point positions is obtained.

[0088] Specifically, in this embodiment, the process of determining whether all target longitudinal steel bars are qualified for one-time placement according to the longitudinal spacing differences and the spacing evaluation value includes:

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

[0090] Step S342, determining whether all target longitudinal steel bars are qualified for the first-time laying process based on the number of unqualified individual bars;

[0091] Wherein, based on the fact that the number of unqualified single bars is 0, it is determined that the overall first-time layout 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 first-time layout 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 roots is obtained.

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

[0094] Step S350, upon determining that the first placement of all target longitudinal reinforcement bars is qualified, starting the second placement operation;

[0095] Step S360: Based on the result of the first determination that the single pair of lengths is unqualified, a feedback signal of type: [actual first cloth operation abnormality] is issued;

[0096] Step S370, when the first-time laying of a single pair of positions is unqualified, determining the first-type feedback signal as "actual first-time 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;

[0097] Step S380: Based on the overall unqualified primary laying, the feedback signal is determined to be [abnormal actual primary laying operation] or [abnormal actual longitudinal steel bar coil straightening] according to the number of unqualified individual bars.

[0098] See 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 based on the numerical change of the actual longitudinal spacing of each monitoring 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, in this embodiment, based on the overall primary laying failure, the process of determining the type of feedback signal as [actual primary laying operation abnormality] or [actual longitudinal steel bar coil straightening abnormality] according to the number of unqualified individual bars includes:

[0103] Step S381: Based on the number of unqualified single yarns being 1, determining that the first type of feedback signal is [abnormality in the actual first cloth operation];

[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 [abnormal straightening of the actual longitudinal steel bar coil].

[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 deviation 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. The recording of 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 Figure 4 As shown in FIG, it is a secondary determination flow chart, wherein the process of performing secondary determination based on the transverse fabric parameters to determine whether to start the intersection welding operation, or issuing corresponding second-type feedback signals based on 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 centerline corresponding to each intersection position;

[0109] Step S530: Fit each intersection center line, and determine whether to start the intersection welding operation based on 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 placement based on 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 based on 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, so as to avoid measurement errors caused by angle deviation;

[0114] During 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 position is qualified; for any actual fitting angle is not within the error range allowed by the actual project, the single-point secondary distribution at the intersection position is unqualified; the number of intersection positions 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, by acquiring an actual layout image and marking the intersection positions, the present invention can accurately identify the intersections of transverse and longitudinal rebars, providing accurate location information for welding operations. By fitting the intersection centerline and determining the actual fitting angle, the accuracy of intersection welding is ensured, thereby improving welding quality. Automatically determining whether to initiate intersection welding reduces manual judgment and operation, improving production efficiency. The quality of material placement at intersections is monitored in real time, and a second-class feedback signal is used to quickly respond to any deviations, allowing for timely adjustments and avoiding production delays. By ensuring that all intersections are properly placed before welding, the process reduces rework and material waste caused by improper placement. By analyzing the number of unqualified angles, the process can distinguish different types of anomalies, such as abnormal transverse rebar coil straightening or secondary placement operations, helping to address the problem in a targeted manner. Accurate intersection welding reduces structural weaknesses caused by improper welding, improving the safety and reliability of the final product, ensuring consistent placement and welding quality at all intersections, and enhancing the uniformity and consistency of the entire prestressed positioning mesh product. The implementation of the secondary determination process brings precise welding preparation, efficient automated 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. In this embodiment, no specific assignment is performed. In addition, the calculation formulas in this embodiment are used to intuitively reflect the adjustment relationship between the various 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] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

[0118] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection 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 straightened and cut in sequence to obtain a number of target transverse steel bars; Placing each target longitudinal steel bar on a conveyable workbench at a fixed longitudinal spacing, obtaining longitudinal distribution parameters, and performing a primary determination based on the longitudinal distribution parameters to determine whether to initiate 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 based on the transverse material distribution parameters to determine whether to start the intersection welding operation, or issuing corresponding second-type feedback signals based on 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 based on the longitudinal cloth parameters to determine to start a secondary cloth operation, or issuing a corresponding type of feedback signal based on the primary determination result, includes: According to the one-time laying result, the actual longitudinal spacing of several single points between any pair of adjacent target longitudinal steel bars is obtained, and according to the actual longitudinal spacing of each single point, whether the length of the adjacent target longitudinal steel bars is qualified for one-time laying is determined; Based on the qualified single pair lengths for one-time laying, calculating the point longitudinal spacing difference between the actual longitudinal spacings of each single point, and determining whether the pair of adjacent target longitudinal steel bars are qualified for one-time laying at the single pair position according to the longitudinal spacing difference of each point and a preset spacing evaluation value; Based on the qualified placement of the single pair of positions in one time, the actual longitudinal spacing between the remaining target longitudinal steel bars is obtained, and the root longitudinal spacing difference between the actual longitudinal spacings is calculated; For each longitudinal spacing difference, determine whether each target longitudinal steel bar is qualified for the overall 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 thread.

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: Obtain the actual longitudinal spacing of each single point of several monitoring points between any pair of adjacent target longitudinal steel bars; 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; 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, calculating the first absolute value of the difference between the single-point actual longitudinal spacing and the longitudinal fixed spacing; Determining whether the monitoring point is qualified based on the absolute value of the first difference and a preset spacing evaluation value; wherein, if the absolute value of the first 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 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 are qualified for one-time placement at a single position based on the longitudinal spacing difference of each point and a preset spacing evaluation value includes: Obtain 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 are qualified for one-time placement at a single position according to the number of unqualified single-point positions; Obtain the number of unqualified individual roots in the longitudinal spacing difference of each root; Whether the overall one-time laying of each target longitudinal steel bar is qualified is determined based on 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 based on the longitudinal cloth parameters to determine to start a secondary cloth operation, or issuing a corresponding type of feedback signal based on the primary determination result, further includes: Based on the determination that the overall first-time placement of each target longitudinal steel bar is qualified, the second-time placement operation is started; Based on the result of the one-time determination that the single pair of lengths is unqualified, a feedback signal is issued: the actual one-time cloth operation is abnormal; When the first-time laying of a single pair of positions is unqualified, the first-type feedback signal is determined to be an abnormality in the actual first-time laying operation or an abnormality in the 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 to be abnormal in the actual first-time laying operation or abnormal in the actual straightening of the longitudinal steel bar coil according to the number of the 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 that the first type of feedback signal is an actual abnormality in a material laying operation or an actual abnormality in the straightening of the longitudinal steel bar coil according to the abnormal change trend of the longitudinal spacing difference at each point includes: 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 based on 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 an actual abnormality in a cloth distribution operation; Based on the abnormal change trend being a fluctuating change trend, it is determined that the first type of feedback signal is an 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 that the first type of feedback signal is an actual abnormality in the first distribution operation or an actual abnormality in the straightening of the longitudinal steel bar coil based on the number of unqualified single bars after the first distribution is unqualified includes: Based on the number of unqualified single pieces being 1, it is determined that the first type of feedback signal is an actual abnormality in a cloth laying operation; 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 abnormal in the actual straightening of the longitudinal steel bar coil.

9. The method for producing a universal flexible integrated prestressed positioning mesh according to claim 8, characterized in that: The process of performing a secondary determination based on the transverse material distribution parameters to determine the start of the intersection welding operation, or issuing a corresponding second-type feedback signal based on the secondary determination result includes: Obtain the actual layout images of the target transverse reinforcement and the target longitudinal reinforcement according to the secondary placement results; Marking the intersection positions of the target transverse reinforcement and each target longitudinal reinforcement according to the actual layout image, and extracting each intersection centerline 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 based on the actual fitting angle; Obtain the number of unqualified angles in each intersection position, and determine to start the intersection welding operation based on the number of unqualified angles, or determine that the second type of feedback signal is an actual secondary material distribution operation abnormality, or an actual transverse steel bar coil straightening abnormality.

Images