Intelligent steel reinforcement cage processing system

Abstract

This invention provides an intelligent rebar cage processing system, including an execution unit controlled in a closed loop by a main control unit. The execution unit includes a rebar feeding mechanism, a rebar cutting mechanism, a threading mechanism, a rebar changing mechanism, an end-face processing mechanism, and a cage weaving mechanism. The rebar feeding mechanism includes a feeding mechanism for supporting and conveying rebar bundles, a horizontal clamping mechanism, and a vertical clamping mechanism located near the rebar cutting mechanism. This invention adds an adaptive tool compensation module, which determines the saw blade's trajectory trend by real-time detection of the saw blade's linear speed, temperature, and dynamic cutting force, thereby performing real-time compensation to prevent the saw blade from deflecting as the feed rate increases, which could lead to excessive radial or lateral forces and saw blade breakage.

Description

Technical Field

[0001] This invention relates to the field of mechanical processing and manufacturing technology, and more particularly to the field of steel cage processing and manufacturing technology, specifically to an intelligent steel cage processing system. Background Technology

[0002] Reinforcing cages are crucial skeletal structures for enhancing the stress and strength of concrete. Currently, reinforcing cage manufacturing primarily employs a combination of traditional manual tying and mechanized production. Mechanized technology, centered on CNC reinforcing cage welding machines, achieves semi-continuous production through automated rebar winding, main bar positioning, and welding processes. Some advanced equipment also incorporates technologies such as visual recognition and laser positioning to improve accuracy. Traditional processes rely on manual rebar cutting, bending, and tying, resulting in high labor intensity and low efficiency. While semi-automated equipment can improve production efficiency, it still requires manual assistance in adjusting parameters and monitoring quality, and its purchase cost is high, with insufficient adaptability to complex and irregularly shaped reinforcing cages. Welding processes are prone to uneven weld strength and embrittlement of the heat-affected zone. While mechanical connection technology can avoid welding defects, it faces challenges such as stringent requirements for sleeve positioning accuracy and increased construction costs. Furthermore, the widespread use of high-strength reinforcing steel further increases processing difficulty. However, the aforementioned cage-weaving process is the final step in the manufacturing of the rebar cage. Before weaving, rebars of different specifications need to be sawn, threaded, and have their ends flattened according to the required cage specifications to facilitate subsequent connections. For example, during the construction of foundation piles and bridge piers, due to the very long length of concrete pours, the rebar cages need to be connected and poured unit by unit, requiring extensive pre-treatment of the rebars before cage weaving. Taking rebar sawing as an example, existing rebar sawing methods mostly involve sawing bundled rebars, primarily using friction disc cutters or sawing machines. For mass production, friction discs are less efficient than sawing machines, resulting in higher wear and tear and poor end-face neatness. Furthermore, friction discs can only handle single bundles of rebar with relatively small diameters. Therefore, in existing technologies, sawing bundles of rebars is primarily done using sawing machines. However, the biggest problem with sawing machines for cutting whole bundles of steel bars is that individual steel bars may break during the sawing process due to misalignment, vibration, or the saw blade becoming skewed as the sawing feed increases. This is one of the biggest and most prominent problems in the steel bar sawing process. Summary of the Invention

[0003] To address the issues of low automation and reliance on manual control in existing rebar cage processing, and the problems of saw jamming, breakage, and blade deflection / breakage due to localized misalignment of bundled rebars during sawing, this application provides an intelligent rebar cage processing system. Specifically, in the rebar bundle sawing process, by improving the tool adaptive compensation mechanism, it effectively reduces or even eliminates the problems of saw blade misalignment, jamming, and breakage during bundle sawing. Simultaneously, it further solves the problems of high reliance on manual labor and low processing efficiency in the rebar cage fabrication process.

[0004] To achieve the above objectives, the technical solution adopted in this application is as follows:

[0005] This invention provides an intelligent rebar cage processing system, comprising an execution unit controlled in a closed loop by a main control unit. The execution unit includes a rebar feeding mechanism, a rebar cutting mechanism, a threading mechanism, a rebar changing mechanism, an end-face processing mechanism, and a cage weaving mechanism. The rebar feeding mechanism includes a feeding mechanism for supporting and conveying rebar bundles, a horizontal clamping mechanism and a vertical clamping mechanism located near the rebar cutting mechanism. The horizontal clamping mechanism has a fixedly mounted support frame, on which a rack is fixedly mounted. The rack is driven and reciprocates along the length of the support frame to clamp the rebar bundles. The clamping head, the vertical clamping mechanism having a gantry frame that moves up and down, the gantry frame and the plane of the support frame forming a space for accommodating the rebar bundle; the rebar cutting mechanism having a saw blade for cutting the rebar bundle, the saw blade being tensioned and driven by a drive wheel and a driven wheel, and a first speed sensor and a second speed sensor for detecting the real-time speed of the drive wheel and the driven wheel respectively; the main control unit includes a protection and early warning module that sends a saw retraction command to the rebar cutting mechanism by comparing the speed difference ΔR between the first speed sensor and the second speed sensor.

[0006] To reduce saw jamming and breakage caused by vibration, displacement, and rebar misalignment, preferably, the main control unit also includes an adaptive tool compensation module for controlling the rebar cutting mechanism. The rebar cutting mechanism also includes an infrared temperature sensor for real-time / intermittent measurement of the saw blade temperature and a triaxial force sensor array for detecting the dynamic cutting force of the saw blade. The calculation of the tool compensation amount ΔL for the rebar cutting mechanism to drive the saw blade to cut is expressed as follows:

[0007] ΔL=k1·T+k2·v 2 +k3·∫F(t)dt

[0008] Wherein, ΔL represents the saw blade compensation amount, including axial and radial compensation components, in mm; T represents the real-time temperature of the saw blade, in °C; v represents the linear velocity of the saw blade, in m / s; F(t) represents the dynamic cutting force, in N; and k1-k3 represent weighting coefficients, determined through dynamic calibration via machine learning.

[0009] To prevent the rebar bundles from slipping or tilting during the feeding process, which could affect the front-end sawing, the feeding mechanism further preferably includes a clamping mechanism for holding the rebar bundles tightly. The clamping mechanism includes clamping units symmetrically installed on both sides along the length of the feeding mechanism. Each clamping unit includes multiple bearing seats A fixedly installed on both sides of the feeding mechanism, and a deflection shaft A rotatably installed in the bearing seats A on the same side. A cutter arm located above the feeding mechanism for pressing the rebar bundles and a support arm A located below the feeding mechanism are fixedly installed on the deflection shaft A. The free end of the support arm A is hinged to a push-pull mechanism A for driving the deflection shaft A to rotate.

[0010] Furthermore, the push-pull mechanism A is a hydraulic rod or an electric telescopic rod, the cutter arm has an arc-shaped structure, and an anti-slip rubber layer is provided on the side near the steel bar bundle. The deflection angle of the deflection shaft A is 45°-90°.

[0011] More preferably, the feeding mechanism includes a frame and a plurality of rollers spaced apart along the length of the frame. The two ends of the rollers are rotatably connected by bearing seats B fixedly installed at both ends of the frame. One end of each roller is equipped with a sprocket A connected by a chain drive. The chain also drives a drive unit A.

[0012] Furthermore, baffles are provided at both ends of the frame to restrict the rolling of the steel bar bundles.

[0013] Preferably, the rebar replacement mechanism includes multiple rebar receiving slots arranged in parallel, multiple rotating shaft frames fixedly arranged between two adjacent rebar receiving slots, a deflection shaft B passing through any rotating shaft frame located on the same axis, and multiple support arms B fixedly arranged on the deflection shaft B. The free end of any support arm B is hinged to a push-pull mechanism B, and the extension and retraction of the push-pull mechanism B drives the support arm B to deflect, flipping the rebar in any rebar receiving slot to another adjacent rebar receiving slot.

[0014] In a further preferred embodiment, the rebar replacement mechanism further includes a plurality of rollers spaced apart within the rebar receiving groove for supporting and moving the rebars. Each roller is coaxially fixedly mounted with a sprocket B, and each sprocket B is driven and connected to the drive unit B via a chain B.

[0015] To improve the continuity of rebar supply and increase the efficiency of the rebar sawing process, preferably, a rebar support frame A is set next to the rebar replacement mechanism for supplying rebars to the rebar replacement mechanism one by one. The rebar support frame A includes a support beam for placing rebars to be threaded / end-faced. A deflection shaft C driven by a drive unit C is set on the side of the support beam near the rebar replacement mechanism. A flipping hook for conveying the rebars to the rebar replacement mechanism one by one is fixedly installed on the deflection shaft C.

[0016] In order to neatly store the rebars that have been threaded and end-faced, preferably, the rebar replacement mechanism is also provided with a rebar support frame B on the side away from the rebar support frame A for storing the rebars that have been threaded and end-faced.

[0017] Beneficial effects:

[0018] 1. This invention, by adding a protection and early warning module, can detect the status of the saw blade in real time during the sawing of steel bar bundles. If the saw blade gets stuck, slips, or the steel bar vibrates beyond the limit, it can immediately retract or stop the saw, thereby effectively solving the problem that existing sawing machines are prone to saw breakage when sawing whole bundles of steel bars.

[0019] 2. This invention adds an adaptive tool compensation module, which judges the saw blade's direction trend by real-time detection of the saw blade's linear speed, temperature, and dynamic cutting force, thereby performing real-time compensation to avoid the saw blade from deflecting as the feed rate increases, which would cause the saw blade to break due to excessive radial or lateral forces.

[0020] 3. This invention compensates for the feed of the cutting tool and monitors the state of the steel bar bundle in real time during the cutting process. This ensures that the saw blade can always cut at a uniform speed along the vertical feed direction, which can basically guarantee the flatness of the cut end face, reduce the amount of cutting at the end face, reduce the pressure on subsequent end face processing, shorten the end face processing time, and further improve efficiency.

[0021] 4. The present invention automatically completes everything from steel bar bundling to feeding and sawing, threading, and end face treatment, without the need for manual intervention. This greatly reduces the human resource input in the steel bar pretreatment process and improves the level of intelligence and efficiency. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is an isometric view of the reinforcing bar feeding mechanism.

[0024] Figure 2 yes Figure 1 Enlarged view of the structure in area A.

[0025] Figure 3 yes Figure 1 Enlarged view of the structure in area B.

[0026] Figure 4 yes Figure 1 The main view.

[0027] Figure 5 yes Figure 4 Enlarged view of the structure in the C region.

[0028] Figure 6 It is an isometric view of the threading and rib-changing mechanism.

[0029] Figure 7 yes Figure 6 Enlarged view of the structure in the middle D region.

[0030] Figure 8 yes Figure 6 Enlarged view of the structure in region E.

[0031] In the diagram: 10-Feeding mechanism; 11-Horizontal clamping mechanism; 111-Support frame; 112-Rack; 113-Clamping head; 12-Vertical clamping mechanism; 13-Clamping mechanism; 131-Push-pull mechanism A; 132-Support arm A; 133-Deflection shaft A; 134-Bearing seat A; 135-Cutter arm; 14-Feeding mechanism; 141-Sprocket A; 142-Bearing seat B; 143-Chain; 144-Roller; 15-Baffle;

[0032] 20 - Beam cutting mechanism; 21 - Saw blade; 30 - Threading mechanism; 40 - Clamping mechanism;

[0033] 50-Rebar replacement mechanism; 51-Rebar receiving groove; 52-Push-pull mechanism B; 53-Support arm B; 54-Spindle frame; 55-Deflection shaft B; 56-Sprocket B; 57-Roller; 58-Chain B; 59-Drive unit B;

[0034] 60-Rebar support frame A; 61-Support beam; 62-Deflection shaft C; 63-Tilting hook; 70-End face treatment mechanism; 80-Rebar support frame B. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0036] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0037] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0038] In the description of this application, it should be noted that the use of terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" to indicate orientation or positional relationships is based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationships commonly used when the product is in use. These terms are used solely for the convenience of describing this application and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the use of terms such as "first" and "second" in the description of this application is only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0039] Furthermore, the use of terms such as "horizontal" and "vertical" in the description of this application does not imply that the component is required to be absolutely horizontal or suspended, but rather that it may be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but rather that it may be slightly tilted.

[0040] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0041] Example 1:

[0042] This embodiment provides an intelligent rebar cage processing system, including an execution unit controlled in a closed loop by a main control unit. The execution unit includes a rebar feeding mechanism 10, a rebar cutting mechanism 20, a threading mechanism 30, a rebar changing mechanism 50, an end-face processing mechanism 70, and a cage weaving mechanism. The rebar feeding mechanism 10 includes a feeding mechanism 14 for supporting and conveying rebar bundles, a horizontal clamping mechanism 11 and a vertical clamping mechanism 12 disposed near the rebar cutting mechanism 20. The horizontal clamping mechanism 11 has a fixedly disposed support frame 111, on which a rack 112 is fixedly disposed, drivingly connected to the rack 112 and reciprocating along the length direction of the support frame 111. The clamping head 113, which opens and closes to hold the steel bar bundle, is movable. The vertical clamping mechanism 12 has a gantry frame that moves up and down. The gantry frame and the plane of the support frame 111 enclose a space for accommodating the steel bar bundle. The steel bar cutting mechanism 20 has a saw blade 21 for cutting the steel bar bundle. The saw blade 21 is tensioned and driven by a drive wheel and a driven wheel. A first speed sensor and a second speed sensor are used to detect the real-time rotational speed of the drive wheel and the driven wheel, respectively. The main control unit includes a protection and early warning module that sends a saw retraction command to the steel bar cutting mechanism 20 by comparing the rotational speed difference ΔR between the first speed sensor and the second speed sensor.

[0043] Working principle:

[0044] See the instruction manual appendix Figure 1-3 , Figure 6 As shown, the workflow of the rebar cage processing system provided in this embodiment is as follows: Bundles or loose finished rebars are placed on the rebar feeding mechanism 10. The rebars are aligned as much as possible with the end closest to the rebar cutting mechanism 20. This alignment serves two purposes: firstly, it avoids cutting the rebar ends, reducing saw blade wear and requiring one less cut; secondly, it saves time and increases processing efficiency; and thirdly, rebars of consistent length ensure greater consistency in the subsequent threading mechanism 30 and rebar replacement mechanism 50, preventing rebar end jamming or interference with other structures. Furthermore, rebars of consistent length result in more standardized rebar cages during the subsequent rebar cage fabrication process.

[0045] After the finished steel bars are placed on the feeding mechanism 10, the feeding mechanism 14 first transports the entire steel bar towards one side of the cutting mechanism 20, stopping the transport when it reaches the preset cutting position. Next, the horizontal clamping mechanism 11 and the vertical clamping mechanism 12 are used to fix the finished steel bar near the cutting position. The fixing method involves first using the horizontal clamping mechanism 11 to horizontally compress the finished steel bar, making it as dense as possible; then using the vertical clamping mechanism 12 to apply vertical compressive force to the steel bar, further compacting it and preventing the steel bar from deflecting due to the lateral force applied by the saw blade 21 during cutting, thus avoiding saw jamming or breakage. (See also...) Figure 1 and Figure 2 As shown, the horizontal clamping mechanism 11 and the vertical clamping mechanism 12 are driven by a motor reduction mechanism or a hydraulic mechanism, which can effectively fix the reinforcing bars. At the same time, they can provide a rigid structure that effectively restricts the movement of the reinforcing bars, which is more stable than flexible wire rope fixing. In practice, it can reduce the misalignment of the reinforcing bars by about 15%. This structure significantly improves the effect compared with steel cable tensioning and fixing in actual cutting applications. The reason why its fixing effect is significantly improved compared with the steel cable tensioning structure is as follows: 1. The horizontal clamping mechanism 11 and the vertical clamping mechanism 12 are fixed to the rebar feeding mechanism 10, so that the left, right, top and bottom of the rebar are restricted by the rigid structure, and there is no possibility of misalignment. This makes the rebar very stable throughout the sawing process. The rebar fixed by the steel cable is generally two bars on the left and right that are pulled together. Although this can press the rebar only on the rebar feeding mechanism 10, the rebar located at the bottom near the sides is prone to a force blind zone. When subjected to the cutting force applied by the saw blade 21, it is easy to misalign laterally, which can easily cause the saw to jam and lead to the breakage of the saw blade 21. During normal sawing, the three speeds of the saw blade 21, the drive wheel and the driven wheel are consistent, and the angular velocities of the drive wheel and the driven wheel are consistent. Therefore, the speed difference ΔR between the first speed sensor and the second speed sensor is 0. When ΔR≠0, it indicates that slippage has occurred between the drive wheel and the saw blade 21. This means that the stress between the rebar and the saw blade 21 increases instantaneously and exceeds the friction between the saw blade 21 and the drive wheel, indicating that the rebar has shifted. When ΔR>ΔR0, it means that the current rebar shift has exceeded the system's allowable range. At this time, the protection and early warning module sends a retraction command to the rebar cutting mechanism 20, causing the saw blade 21 to retract. This prevents the saw blade from breaking due to continued cutting while the rebar is shifted, effectively solving the problem of saw jamming. Here, ΔR0 represents the system's preset speed difference value. In this embodiment, the threading mechanism 30, the rebar changing mechanism 50, the end face processing mechanism 70, and the cage weaving mechanism adopt existing technology without modification.

[0046] Example 2:

[0047] In this embodiment, to avoid the problem of excessive lateral force on the saw blade 21 leading to saw breakage due to deviation between the actual sawing trajectory and the preset sawing trajectory, and to reduce the problems of saw jamming and breakage caused by vibration, displacement, and rebar misalignment, this embodiment further optimizes the main control unit based on embodiment 1. Specifically, the main control unit also includes a module for controlling the rebar cutting mechanism 20 to perform adaptive tool compensation. The rebar cutting mechanism 20 also includes an infrared temperature sensor for real-time / intermittent measurement of the temperature of the saw blade 21, and a triaxial force sensor array for detecting the dynamic cutting force of the saw blade 21. The calculation of the tool compensation amount ΔL for the rebar cutting mechanism 20 to drive the saw blade 21 to cut is expressed as follows:

[0048] ΔL=k1·T+k2·v 2 +k3·∫F(t)dt

[0049] Wherein, ΔL represents the saw blade compensation amount, including axial and radial compensation components, in mm; T represents the real-time temperature of the saw blade, in °C; v represents the linear velocity of the saw blade, in m / s; F(t) represents the dynamic cutting force, in N; and k1-k3 represent weighting coefficients, determined through dynamic calibration via machine learning.

[0050] In this embodiment, the feed rate and direction of the saw blade 21 are adjusted in real-time in a closed loop based on the actual working state of the saw blade 21, rather than a fixed linear feed cut. Instead, adjustments are made dynamically according to the actual sawing conditions. For example, during actual sawing, as the feed rate increases, the actual sawing trajectory of the saw blade 21 will deviate from the preset position. The actual cutting edge, due to factors such as the vibration of the reinforcing bar, will not be a straight line, leading to uneven stress on the saw blade 21. If the position and direction of the saw blade are not adjusted in time, further increasing the feed rate will exacerbate the deviation, eventually causing the saw blade 21 to break. This embodiment establishes a closed-loop control mechanism for the tool compensation amount ΔL by real-time detection of the saw blade 21's speed, temperature, and cutting force. This mechanism compensates for the saw blade 21 in real time, correcting even slight deviations promptly and ensuring that the actual sawing trajectory remains consistent with the preset trajectory, thus avoiding saw breakage due to excessive deviation. In this embodiment, the real-time temperature of the saw blade 21 is measured using a non-contact temperature monitoring module, such as an infrared thermal imager and a contact thermocouple, which enables temperature compensation to counteract axial deviations caused by thermal expansion. Simultaneously, the rotational speed and radius of the driven wheel, collected by the second speed sensor, allow for real-time calculation of the actual linear velocity of the saw blade 21, thus enabling speed compensation. The dynamic cutting force F(t) reflects fluctuations in the machining load. Using a triaxial force sensor array and a piezoelectric force gauge, data is collected to compensate for the actual feed force and direction of the saw blade 21, thereby correcting trajectory deviations caused by cutting force fluctuations in real time.

[0051] Example 3:

[0052] This embodiment is an improvement upon any of the above embodiments, made to avoid the problem of the rebar bundle slipping or tilting during the rebar bundling process, which would affect the front-end sawing. See the appendix to the instruction manual for details. Figures 1-8 As shown, the rebar feeding mechanism 10 further includes a clamping mechanism 13 for clamping the rebar bundle. The clamping mechanism 13 includes clamping units symmetrically installed on both sides along the length of the feeding mechanism 14. Each clamping unit includes multiple bearing seats A134 fixedly installed on both sides of the feeding mechanism 14, and a deflection shaft A133 rotatably installed in the bearing seat A134 on the same side. A cutter arm 135 for pressing the rebar bundle is fixedly installed above the feeding mechanism 14, and a support arm A132 is fixedly installed below the feeding mechanism 14. The free end of the support arm A132 is hinged to a push-pull mechanism A131 for driving the deflection shaft A133 to rotate. See the appendix of the specification for details. Figures 2-3 As shown, after the reinforcing bars are placed, the main stress point of the reinforcing bar bundle is at the head, i.e., near the end of the cutting mechanism 20. However, due to the high-frequency vibration generated during cutting, the tail of the reinforcing bars will also vibrate and shift. To avoid the impact of vibration and shifting on the sawing of the reinforcing bars, the entire bundle of reinforcing bars needs to be fixed. Before placing the reinforcing bars, the push-pull mechanism A131 is in a retracted state, and the deflection shaft A133 is rotated with the support arm A132 as the lever arm, thereby driving the cutter arm 135 to rotate to a vertical or near-vertical state, so as to facilitate the placement of the reinforcing bar bundle on the feeding mechanism 14. Then the push-pull mechanism A131 extends again, driving the deflection shaft A133 in the opposite direction to make the cutter arm 135 fix and press the reinforcing bar bundle. The push-pull mechanism A131 can be pneumatic, hydraulic or electric screw, and its size is not limited, as long as it can meet the purpose of fixing the reinforcing bars. Those skilled in the art can freely choose the specific structural type of the push-pull mechanism A131.

[0053] Furthermore, the push-pull mechanism A131 is a hydraulic rod or an electric telescopic rod, the cutter arm 135 is an arc-shaped structure, and an anti-slip rubber layer is provided on the side near the steel bar bundle. The deflection angle of the deflection shaft A133 is 45°-90°. The larger the angle, the greater the opening when placing the steel bar.

[0054] In this embodiment, please refer to the appendix to the specification. Figure 3As shown, the feeding mechanism 14 includes a frame and a plurality of rollers 144 spaced apart along the length of the frame. The two ends of each roller 144 are rotatably connected by bearing seats B142 fixedly mounted at both ends of the frame. Each roller 144 has a sprocket A141 mounted at one end, driven by a chain 143. The chain 143 also drives a drive unit A. To prevent slippage and improve feeding accuracy, a wear-resistant rubber layer is fixedly provided on the surface of each roller 144, with a thickness of not less than 3 mm.

[0055] To further standardize the position of the rebar bundles and ensure they are placed flat on the feeding mechanism 14 for axial feeding, please refer to the appendix of the instruction manual. Figure 3 As shown, baffles 15 are also provided at both ends of the frame to restrict the rolling of the steel bar bundles.

[0056] In this embodiment, as Figures 7-8 As shown, the rebar replacement mechanism 50 includes multiple rebar receiving slots 51 arranged in parallel, multiple rotating shaft frames 54 fixedly arranged between two adjacent rebar receiving slots 51, and a deflection shaft B55 passing through any rotating shaft frame 54 located on the same axis. The deflection shaft B55 is fixedly provided with multiple support arms B53. The free end of any support arm B53 is hinged to a push-pull mechanism B52, and the extension and retraction of the push-pull mechanism B52 drives the support arm B53 to deflect, flipping the rebar in any rebar receiving slot 51 to another adjacent rebar receiving slot 51.

[0057] In a further preferred embodiment, the rebar replacement mechanism 50 further includes a plurality of rollers 57 spaced apart within the rebar receiving groove 15 for supporting and moving the rebars. Each roller 57 is coaxially fixedly mounted with a sprocket B56, and each sprocket B56 is driven and connected to the drive unit B59 via a chain B58. Since threading and end-face treatment of reinforcing bars can only be performed on a single bar at a time, during threading, after the roller 57 axially transports the reinforcing bar located in the reinforcing bar receiving groove 51 to the predetermined position of the threading mechanism 30, the clamping mechanism 40 fixes and clamps the reinforcing bar, and the threading mechanism 30 performs threading on the reinforcing bar. After threading is completed, the roller 57 rotates in the opposite direction, moving the reinforcing bar to the position before threading. Then, through the extension and retraction of the push-pull mechanism B52, the support arm B53 drives the threaded reinforcing bar to flip and place it into the adjacent reinforcing bar receiving groove until it enters the reinforcing bar receiving groove 51 aligned with the end-face treatment mechanism 70. Again, the rotation of the roller 57 is used to send the reinforcing bar to the predetermined position of the end-face treatment mechanism 70 for fixing, and the end face is flushed. There are also various existing technologies for this process, such as grinding, cutting, and other flushing solutions, which will not be detailed here. The main improvement in this embodiment is the flipping of the reinforcing bars; in addition, it is worth emphasizing that the driving relationship between the rollers 57 in each reinforcing bar receiving groove 51 and the rollers 57 in the adjacent reinforcing bar receiving grooves 51 is independent and controlled by the main control unit of the system.

[0058] To improve the continuity of rebar supply and increase the efficiency of the rebar sawing process, this embodiment also includes a rebar support frame A60 disposed beside the rebar replacement mechanism 50 for supplying rebars to the rebar replacement mechanism 50 one by one. See [reference needed] Figure 6 As shown, the rebar support frame A60 includes a support beam 61 for placing rebars to be threaded / end-face treated. The support beam 61 is provided with a deflection shaft C62 driven by a drive unit C on the side near the rebar replacement mechanism 50. A flipping hook 63 for conveying the rebars one by one to the rebar replacement mechanism 50 is fixedly installed on the deflection shaft C62.

[0059] To organize and store the threaded and end-faced rebars, see [link / reference]. Figure 6 As shown, the rebar replacement mechanism 50 is further provided with a rebar support frame B80 on the side away from the rebar support frame A60 for supporting the rebars that have been threaded and end-face treated.

[0060] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An intelligent reinforcement cage processing system, comprising an execution unit closed-loop controlled by a master control unit, the execution unit comprising a reinforcing bar feeding mechanism (10), a reinforcing bar cutting mechanism (20), a wire sleeving mechanism (30), a reinforcing bar changing mechanism (50), an end face processing mechanism (70) and a cage weaving mechanism, characterized in that: The rebar feeding mechanism (10) includes a feeding mechanism (14) for supporting and conveying the rebar bundles, a horizontal clamping mechanism (11) and a vertical clamping mechanism (12) disposed near the rebar cutting mechanism (20). The horizontal clamping mechanism (11) has a fixedly disposed support frame (111), on which a rack (112) is fixedly disposed. A clamping head (113) is drivenly connected to the rack (112) and reciprocates along the length of the support frame (111) to clamp the rebar bundles. The vertical clamping mechanism (12) has a vertical movement function. The portal frame and the plane of the support frame (111) form a space for accommodating the steel bar bundle; the steel bar cutting mechanism (20) has a saw blade (21) for cutting the steel bar bundle, the saw blade (21) is tensioned and driven by a drive wheel and a driven wheel, and a first speed sensor and a second speed sensor for detecting the real-time speed of the drive wheel and the driven wheel respectively; the main control unit includes a protection and early warning module that sends a saw retraction command to the steel bar cutting mechanism (20) by comparing the speed difference ΔR between the first speed sensor and the second speed sensor; The main control unit also includes a module for controlling the trephine cutting mechanism (20) to perform adaptive tool compensation. The trephine cutting mechanism (20) also includes an infrared temperature sensor for real-time / intermittent measurement of the saw blade (21) temperature and a triaxial force sensor array for detecting the dynamic cutting force of the saw blade (21). The tool compensation amount by which the trephine cutting mechanism (20) drives the saw blade (21) to perform cutting. The calculation is expressed as follows: ； in, This represents the saw blade compensation amount, including axial and radial compensation components, in mm. This represents the real-time temperature of the saw blade, in °C. This represents the linear velocity of the saw blade, in m / s. Represents dynamic cutting force, unit: N; The representative weighting coefficient is determined through dynamic calibration using machine learning. The feeding mechanism (10) further includes a clamping mechanism (13) for clamping the steel bar bundle. The clamping mechanism (13) includes clamping units symmetrically installed on both sides along the length of the feeding mechanism (14). Each clamping unit includes multiple bearing seats A (134) fixedly installed on both sides of the feeding mechanism (14) and a deflection shaft A (133) rotatably installed in the bearing seat A (134) on the same side. The deflection shaft A (133) is respectively fixedly provided with a knife arm (135) above the feeding mechanism (14) for clamping the steel bar bundle and a support arm A (132) below the feeding mechanism (14). The free end of the support arm A (132) is hinged to a push-pull mechanism A (131) for driving the deflection shaft A (133) to rotate.

2. The intelligent rebar cage processing system according to claim 1, characterized in that: The push-pull mechanism A (131) is a hydraulic rod or an electric telescopic rod, the knife arm (135) is an arc-shaped structure, and an anti-slip rubber layer is provided on the side near the steel bar bundle. The deflection angle of the deflection shaft A (133) is 45°-90°.

3. The intelligent rebar cage processing system according to claim 1, characterized in that: The feeding mechanism (14) includes a frame and a plurality of rollers (144) spaced apart along the length of the frame. The two ends of the rollers (144) are rotatably connected by bearing seats B (142) fixedly installed at both ends of the frame. One end of any roller (144) is equipped with a sprocket A (141) driven by a chain (143). The chain (143) is also driven by a drive unit A.

4. The intelligent rebar cage processing system according to claim 3, characterized in that: The frame is also equipped with baffles (15) at both ends to restrict the rolling of the steel bar bundles.

5. The intelligent steel cage processing system according to any one of claims 1-4, characterized in that: The rebar replacement mechanism (50) includes multiple rebar receiving slots (51) arranged in parallel, multiple rotating shafts (54) fixedly arranged between two adjacent rebar receiving slots (51), and a deflection shaft B (55) passing through any rotating shaft (54) located on the same axis. The deflection shaft B (55) is fixedly provided with multiple support arms B (53). The free end of any support arm B (53) is hinged to the push-pull mechanism B (52) and the extension and retraction of the push-pull mechanism B (52) drives the support arm B (53) to deflect and flip the rebar in any rebar receiving slot (51) to another adjacent rebar receiving slot (51).

6. The intelligent rebar cage processing system according to claim 5, characterized in that: The rebar replacement mechanism (50) also includes multiple rollers (57) spaced apart in the rebar receiving groove (51) for supporting and moving the rebar. Each roller (57) is coaxially fixedly mounted with a sprocket B (56), and each sprocket B (56) is driven and connected to the drive unit B (59) through a chain B (58).

7. The intelligent rebar cage processing system according to claim 5, characterized in that: It also includes a rebar support frame A (60) set next to the rebar replacement mechanism (50) for supplying rebars to the rebar replacement mechanism (50) one by one. The rebar support frame A (60) includes a support beam (61) for placing rebars to be threaded / end-face treated. The support beam (61) is provided with a deflection shaft C (62) driven by a drive unit C on the side near the rebar replacement mechanism (50). A flipping hook (63) for conveying the rebars to the rebar replacement mechanism (50) one by one is fixedly installed on the deflection shaft C (62).

8. The intelligent rebar cage processing system according to claim 7, characterized in that: The rebar replacement mechanism (50) is further provided with a rebar support frame B (80) on the side away from the rebar support frame A (60) for supporting the rebars that have been threaded and end-face treated.

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