Steel drill bending deformation on-line straightening device and method based on air cooling function

Abstract

The application provides a kind of based on the on-line correction device and correction method of steel drill bending deformation of air cooling function, it is related to the automatic technology field of ore smelting furnace, system includes: upper roller frame, lower roller frame, straightening roll, air cooling mounting plate, worm drive assembly and nozzle, air cooling mounting plate is used to connect the middle plate of two side plates, and air cooling pipeline is arranged on the middle plate, the two side plates of air cooling mounting plate are installed on the two side walls of upper roller frame by first rotating shaft, and the middle plate of air cooling mounting plate blocks the top end side of upper roller frame;Worm drive assembly is installed on upper roller frame, and the arc-shaped edge of one side plate of air cooling mounting plate is provided with worm gear type gear teeth, and the gear teeth support is engaged with the worm in worm drive assembly;The mechanism combines mechanical straightening with air cooling module, improves the straightening efficiency of steel drill, prolongs the service life of steel drill, and improves production efficiency.

Description

Technical Field

[0001] This invention relates to the field of submerged arc furnace automation, and in particular to an online correction device and method for bending deformation of steel bars based on air cooling. Background Technology

[0002] In the tapping process of an electric arc furnace, the tapping robot plays a crucial role. The hole-pulling operation is completed by the robot repeatedly pushing and pulling the steel rod through the furnace hole. However, the steel rod operates in a high-temperature material environment, and the area in contact with the material at the front is easily deformed by heat, which seriously affects the accuracy of subsequent operations and thus interferes with the overall quality and efficiency of the electric arc furnace tapping operation.

[0003] The steel rod straightening mechanism currently used in submerged arc furnaces straightens steel rods solely through mechanical compression, lacking rapid cooling after the rods have deformed due to heat. This results in the rods remaining in a high-temperature deformed state for extended periods, leading to low straightening efficiency and failing to meet the demands of modern industry for high-efficiency submerged arc furnace production. Therefore, there is an urgent need to improve the existing steel rod straightening mechanism to enhance its performance. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides an online straightening device and method for bending deformation of steel rods based on air cooling. This method combines mechanical straightening with an air cooling module to improve steel rod straightening efficiency, extend steel rod service life, and increase production efficiency. Specifically, it includes:

[0005] An online correction device for bending deformation of steel bars based on air cooling function includes:

[0006] The upper roller frame and the lower roller frame are rotatably connected to achieve opening and closing;

[0007] A straightening roller, wherein at least one straightening roller is installed in the upper roller frame and at least one straightening roller is installed in the lower roller frame;

[0008] The air-cooled mounting plate is integrally formed and U-shaped. The two parallel side plates of the air-cooled mounting plate are P-shaped. An air-cooled pipe is provided on the middle plate inside the air-cooled mounting plate for connecting the two side plates. The two side plates of the air-cooled mounting plate are mounted on the two side walls of the upper roller frame through a first rotating shaft. The middle plate of the air-cooled mounting plate blocks the top end of the upper roller frame.

[0009] A worm gear drive assembly is mounted on the upper roller frame. The arc-shaped edge of one side plate of the air-cooled mounting plate is provided with worm gear teeth, which support meshing with the worm inside the worm gear drive assembly.

[0010] Nozzles are connected to the outlet of each air-cooled duct. The nozzles are mounted on the air-cooled mounting plate via an angle adjustment assembly, and the angle of the nozzles can be adjusted up and down.

[0011] The worm gear drive assembly adjusts the overall rotation angle of the air-cooled mounting plate by rotating the meshing side plate.

[0012] Optionally, the air-cooled duct includes: a main duct and branch ducts;

[0013] The main pipe is L-shaped and is installed on the back of the middle plate of the air-cooled mounting plate;

[0014] The branch pipes are distributed on both sides of the main pipe and are connected to the main pipe, and the multiple branch pipes are arranged in a concentric arc shape;

[0015] The air-cooled mounting plate is provided with multiple through holes, and each branch pipe is connected to the nozzle through the corresponding through hole.

[0016] Optionally, the angle adjustment assembly includes: a mounting ear, a nozzle base, a second rotating shaft, and a spring;

[0017] Mounting ears are installed on both sides of each through hole, and a nozzle base is provided between the mounting ears on both sides of each through hole. The nozzle base is installed between the mounting ears via a second rotating shaft.

[0018] The nozzle base is provided with a meshing tooth on one side, and the meshing tooth of the nozzle base is supported in meshing with the meshing tooth on the mounting ear on the same side;

[0019] A spring end fixing groove is provided on the other side of the nozzle base. A spring end fixing groove is provided on the mounting ear of the nozzle base opposite to the meshing teeth. The spring is sleeved on the second rotating shaft and its two ends are respectively installed in the spring end fixing groove of the nozzle base and the spring end fixing groove of the mounting ear on the same side.

[0020] The nozzle base is provided with a through port communicating with the nozzle, and the nozzle is mounted on the nozzle base;

[0021] When the rotation direction of the nozzle is adjusted up and down, the nozzle base is driven to press against the spring, causing the meshing teeth of the nozzle base to separate from the meshing teeth on the mounting ear. The nozzle base is rotated up and down to rotate to the target angle, and the meshing teeth on the nozzle base are driven to engage with the meshing teeth on the mounting ear, so that the nozzle base stays at the target angle position.

[0022] Optionally, the worm drive assembly includes: a motor and a worm;

[0023] The motor is mounted on the upper roller frame;

[0024] The worm gear is connected to the output end of the motor;

[0025] The worm gear supports driving the gear teeth to rotate in the forward or reverse direction.

[0026] The worm gear drive assembly also includes a bracket;

[0027] The bracket is mounted on the upper roller frame and is used to mount the end of the worm gear away from the motor. The end of the worm gear is supported for rotation through the mounting hole of the bracket.

[0028] Optionally, the longitudinal section of the upper roller frame is set in a right-angled U-shape, and the lower opening of the upper roller frame is connected to the lower roller frame; the edges of the two side plates of the upper roller frame are provided with fan-shaped grooves, and the two side plates of the air-cooled mounting plate are respectively installed in the two fan-shaped grooves;

[0029] The lower roller frame includes a first vertical plate, a second vertical plate, a third vertical plate, and a fourth vertical plate;

[0030] The first upright plate and the second upright plate are arranged in right-angled trapezoids, and the first upright plate and the second upright plate are arranged in parallel. The ends of the right-angled sides of the first upright plate and the second upright plate are connected by a third upright plate.

[0031] The two ends of the fourth upright plate are respectively connected to the middle of the first upright plate and the middle of the second upright plate, and the fourth upright plate and the third upright plate are arranged in parallel.

[0032] The space enclosed by the bottom of the first upright plate, the second upright plate, and the third upright plate is sealed by the bottom plate.

[0033] Optionally, it also includes a hinge assembly and a locking assembly;

[0034] The hinge assembly includes a first axis mounting lug, a second axis mounting lug, and a third rotating shaft;

[0035] Two first shaft mounting lugs are mounted on the side of the fourth upright plate opposite to the second upright plate;

[0036] Two first shaft mounting lugs are mounted on the side wall of the upper roller frame;

[0037] Two first shaft mounting ears are positioned between two second shaft mounting ears, and the first shaft mounting ears and the first shaft mounting ears;

[0038] The two ends of the third rotating shaft are respectively installed in two second shaft mounting ears, and the shaft body of the third rotating shaft passes through two first shaft mounting ears;

[0039] The locking assembly includes a locking lug, a locking block, and a transverse insert;

[0040] The locking lugs are installed on the side wall of the upper roller frame, and the locking block is installed on the third vertical plate. When the upper roller frame and the lower roller frame are fastened together, the locking block is positioned between the two locking lugs and the through holes on the two locking lugs are aligned. After the locking lugs are inserted horizontally, the bottom end of the locking block abuts against the upper surface of the horizontal insertion.

[0041] Optionally, two straightening rollers are provided in the upper roller frame and two straightening rollers are provided in the lower roller frame;

[0042] When the upper roller frame and the lower roller frame are engaged, the two straightening rollers inside the upper roller frame are positioned between the two straightening rollers of the lower roller frame.

[0043] Positioning grooves are provided on the first rotating shaft, the third rotating shaft and the rotating shaft of each straightening roller. Each positioning groove is perpendicular to its own axis and is located at the end. A baffle is installed in each positioning groove.

[0044] For each positioning slot, one end of the baffle is inserted into the positioning slot;

[0045] The other end of the baffle on the first rotating shaft is fixed to the P-shaped side plate of the air-cooled mounting plate;

[0046] The other end of the baffle on the straightening roller inside the upper roller frame is fixed to the side wall of the upper roller frame;

[0047] The other end of the baffle on the straightening roller inside the lower roller frame is fixed to the side wall of the upper roller frame;

[0048] The other end of the baffle on the third rotating shaft is fixed to the side wall of the second shaft mounting lug.

[0049] In addition, a high-temperature wear-resistant layer is provided on the outer surface of each straightening roll. The high-temperature wear-resistant layer is a metal ceramic coating, a weld overlay alloy layer, or a thermal spray alloy layer. The high-temperature threshold of the high-temperature wear-resistant layer is not less than 300°C, which effectively improves the service life of the straightening roll. The outer surface of the straightening roll includes the surface of the positioning groove.

[0050] A method for online correction of bending deformation of steel rods based on air cooling function, comprising the aforementioned steel rod correction device, and further comprising:

[0051] S1. Set up a steel rod straightening device at the target location, connect the blower, air compressor and flow regulating valve to the air-cooled pipe of the steel rod straightening device, and place an industrial camera and infrared thermal imager in the environment where the target location is located.

[0052] S2. Based on the recognition results of the industrial camera, the steel wire model is obtained, and the initial angle adjustment range and the high-temperature area coverage section are obtained according to the steel wire model.

[0053] When the steel drill type is If the diameter is 10mm × 1.5m, the initial angle adjustment range is 25° ± 5°, and the high-temperature zone covers the section from 0 to 30cm from the tip of the steel rod.

[0054] When the steel drill type is If the diameter is 20mm × 2.0m, the initial angle adjustment range is 30° ± 5°, and the high-temperature zone covers the section from 0 to 50cm from the tip of the steel rod.

[0055] When the steel drill type is If the diameter is 30mm × 2.5m, the initial angle adjustment range is 40° ± 5°, and the high-temperature zone covers the section from 0 to 60cm from the tip of the steel rod.

[0056] When the steel drill type is If the diameter is 40mm × 3.0m, the initial angle adjustment range is 50° ± 5°, and the high-temperature zone covers the section from 0 to 80cm from the tip of the steel rod.

[0057] When the steel drill type is If the diameter is 50mm × 3.5m, the initial angle adjustment range is 60° ± 5°, and the high-temperature zone covers the section from 0 to 100cm from the tip of the steel rod.

[0058] S3. Adjust the nozzle in the steel rod straightening device to initially align with the axis of the steel rod. Based on the initial angle adjustment range, drive the air-cooled mounting plate to rotate through the worm gear drive assembly and bring the nozzle closer to the high-temperature area covered section.

[0059] S4. Based on the infrared thermal imager, the temperature distribution image of the steel rod surface is obtained, and the nozzle is aimed at the highest point of the steel rod surface temperature by driving the worm gear drive assembly.

[0060] S5. Adjust the flow rate and pressure in the air-cooled pipe through the flow regulating valve, and cool the highest point of the steel rod surface through the nozzle. Repeat S3 until the temperature of the highest point of the steel rod surface is less than 200°.

[0061] Optionally, the number of nozzles is 15.

[0062] The above technical solution has at least the following advantages compared with the existing technology:

[0063] Integrated online cooling and straightening: The high-temperature steel rod is cooled in real time through the air-cooling module, which reduces the temperature of the steel rod and extends its service life.

[0064] Quick-change structure: The openable and closable structure of the upper and lower roller frames, combined with the wedge block connection, enables quick replacement of steel rods and improves work efficiency.

[0065] Multi-angle adjustable cooling system: The nozzles can be adjusted to multiple angles through an elastic adjustment mechanism, which can adjust the cooling angle according to the diameter and bending of the steel rod to ensure uniform cooling effect.

[0066] High temperature and wear resistant design: The high temperature and wear resistant layer on the surface of the straightening roller can withstand temperatures above 300℃, which effectively improves the service life of the straightening roller and reduces maintenance costs.

[0067] Safety protection structure: The U-shaped setting (top cap) of the upper roller frame effectively blocks splashes and heat radiation inside the furnace, protecting the equipment and operators.

[0068] This invention uses coarse and fine adjustment angles to align with the highest temperature zone, and then cools down sequentially according to the temperature range to prevent deformation.

[0069] In summary, this invention has a reasonable structure and is easy to operate. It can effectively solve the problem of online straightening of high-temperature steel rods, improve the automation level and production efficiency of furnace exit operations, and has broad application prospects. Attached Figure Description

[0070] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0071] Figure 1 This is a first-view structural diagram of one embodiment of the present invention;

[0072] Figure 2 This is a second-view structural schematic diagram of one embodiment of the present invention;

[0073] Figure 3 This is a first-view exploded view of one embodiment of the present invention;

[0074] Figure 4 This is a second-view exploded view of one embodiment of the present invention;

[0075] Figure 5 This is a schematic diagram of a partial structure of a nozzle according to one embodiment of the present invention;

[0076] Figure 6 This is a schematic diagram of the meshing tooth structure according to one embodiment of the present invention.

[0077] Figure label:

[0078] 1. Upper roller frame; 11. Baffle; 2. Lower roller frame; 21. First vertical plate; 22. Second vertical plate; 23. Third vertical plate; 24. Fourth vertical plate; 25. Base plate; 3. Straightening roller; 4. Air-cooled mounting plate; 41. Gear tooth; 42. Intermediate plate; 43. First rotating shaft; 5. Nozzle; 61. Main pipe; 62. Branch pipe; 71. Mounting ear; 72. Nozzle base; 73. Second rotating shaft; 74. Spring; 75. Meshing tooth; 81. Worm gear; 82. Motor; 83. Bracket; 91. First shaft mounting ear; 92. Second shaft mounting ear; 93. Third rotating shaft; 101. Locking ear; 102. Locking block; 103. Horizontal insert; a. Positioning groove; b. Baffle plate. Detailed Implementation

[0079] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0080] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning understood by one of ordinary skill in the art to which this invention pertains. The terms “first,” “second,” and similar terms used in this invention do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms “an,” “a,” or “the,” and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms “comprising,” “including,” or “including,” and similar terms mean that the element or object preceding the word encompasses the element or object listed following the word and its equivalents, without excluding other elements or objects. The terms “connected,” “linked,” or “connected,” and similar terms are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect.

[0081] The purpose of this invention is to provide a compact and easy-to-operate online straightening mechanism for steel rods. This mechanism can effectively cool the steel rods at high temperatures and achieve rapid straightening of the steel rods through a multi-roller straightening structure. It also facilitates quick replacement and maintenance of the steel rods. Specifically, this invention includes:

[0082] The present invention provides, in a first aspect, an online straightening device for bending deformation of steel bars based on air cooling, comprising: an upper roller frame 1, a lower roller frame 2, a straightening roller 3, an air-cooled mounting plate 4, a worm gear drive assembly, and a nozzle 5. The upper roller frame 1 and the lower roller frame 2 are rotatably connected to achieve opening and closing. At least one straightening roller 3 is installed inside the upper roller frame 1, and at least one straightening roller 3 is installed inside the lower roller frame 2. The air-cooled mounting plate 4 is integrally formed and U-shaped. The two parallel side plates of the air-cooled mounting plate 4 are P-shaped. An air-cooling pipe is provided on the intermediate plate 42 inside the air-cooled mounting plate 4 for connecting the two side plates. The two side plates of plate 4 are mounted on the two side walls of the upper roller frame 1 via the first rotating shaft 43. The middle plate 42 of the air-cooled mounting plate 4 blocks the top end of the upper roller frame 1. The worm gear drive assembly is mounted on the upper roller frame 1. The arc-shaped edge of one side plate of the air-cooled mounting plate 4 is provided with worm gear teeth 41, which support meshing with the worm 81 in the worm gear drive assembly. The outlet of each air-cooled pipe is connected to a nozzle 5. The nozzle 5 is mounted on the air-cooled mounting plate 4 via an angle adjustment assembly, and the angle of the nozzle 5 can be adjusted up and down. The worm gear drive assembly adjusts the overall rotation angle of the air-cooled mounting plate 4 by driving the meshing side plates to rotate.

[0083] This invention is based on the upper roller frame 1 and the lower roller frame 2 being rotatably connected on one side by a hinge assembly, and forming an openable structure on the other side by a locking assembly. The locking assembly is used for quick loading and unloading of the steel rod. The longitudinal section of the upper roller frame 1 is set in a right-angled U-shape and is inverted as a whole, that is, it is set with a top and an opening at the bottom. The openings at both ends of the upper roller frame 1 are respectively equipped with a baffle 11 and a wind-cooled mounting plate 4. The baffle 11 is detachably installed at the front end of the upper roller frame 1 by a bolt group. The straightening rollers 3 are respectively installed at the corresponding positions of the upper roller frame 1 and the lower roller frame 2 for multi-roller straightening of the steel rod.

[0084] This invention is based on the upper roller frame 1 and the lower roller frame 2 being rotatably connected on one side by a hinge assembly, and forming an openable structure on the other side by a locking assembly. The locking assembly is used for quick loading and unloading of the steel rod. The longitudinal section of the upper roller frame 1 is set in a right-angled U-shape and is inverted as a whole, that is, it is set with a top and an opening at the bottom. The openings at both ends of the upper roller frame 1 are respectively equipped with a baffle 11 and a wind-cooled mounting plate 4. The baffle 11 is detachably installed at the front end of the upper roller frame 1 by a bolt group. The straightening rollers 3 are respectively installed at the corresponding positions of the upper roller frame 1 and the lower roller frame 2 for multi-roller straightening of the steel rod.

[0085] In one specific embodiment, the air-cooled duct includes a main duct 61 and branch ducts 62. The main duct 61 is L-shaped and is installed on the back of the middle plate 42 of the air-cooled mounting plate 4. The branch ducts 62 are distributed on both sides of the main duct 61 and communicate with it, with multiple branch ducts 62 arranged in a concentric arc. The air-cooled mounting plate 4 has multiple through holes, and each branch duct 62 communicates with a nozzle 5 through a corresponding through hole. Up to 15 nozzles 5 can be installed.

[0086] The main pipe 61 is connected to an air source system, which includes a blower, a compressed air tank, and a flow regulating valve assembly. The flow regulating valve assembly is used to regulate the flow rate and pressure of the cooling airflow. The inlet of the main pipe 61 supports the connection of an air compressor and a blower, and supports the installation of flow regulating valves. The connection method between the air compressor, blower, flow regulating valves, and the inlet of the main pipe 61 is prior art and will not be described in detail in this application.

[0087] In one specific embodiment, the angle adjustment assembly includes: a mounting ear 71, a nozzle base 72, a second rotating shaft 73, and a spring 74;

[0088] Mounting lugs 71 are installed on both sides of each through hole, and a nozzle base 72 is provided between the mounting lugs 71 on both sides of each through hole. The nozzle base 72 is installed between the mounting lugs 71 via a second rotating shaft 73. A meshing tooth 75 is provided on one side of the nozzle base 72, and the meshing tooth 75 of the nozzle base 72 supports meshing with the meshing tooth 75 on the mounting lug 71 on the same side. A spring 74 end-side fixing groove is provided on the other side of the nozzle base 72. A spring 74 end-side fixing groove is provided on the mounting lug 71 of the nozzle base 72 opposite to the meshing tooth 75. The spring 74 is sleeved on the second rotating shaft 73, and its two ends are respectively installed in the spring 74 end-side fixing groove of the nozzle base 72 and the spring 74 end-side fixing groove of the mounting lug 71 on the same side. A through port communicating with a nozzle 5 is provided on the nozzle base 72, and the nozzle 5 is installed on the nozzle base 72.

[0089] Because the multiple branch pipes 62 are arranged in a concentric arc, the nozzle bases 72 are arranged in a ring array with the projection of the steel rod in the vertical plane as the center. The spray direction of the nozzles 5 can be adjusted along the radial direction of the nozzle bases 72. This structure can achieve all-round cooling of the steel rod, effectively reduce the temperature of the steel rod, and improve the straightening effect.

[0090] When the rotation direction of the nozzle 5 is adjusted up and down, the nozzle base 72 is driven to press against the spring 74, causing the meshing teeth 75 of the nozzle base 72 to disengage from the meshing teeth 75 on the mounting ear 71. Rotating the nozzle base 72 up and down causes it to reach the target angle, and the meshing teeth 75 on the nozzle base 72 engage with the meshing teeth 75 on the mounting ear 71, causing the nozzle base 72 to remain at the target angle. This structure allows the nozzle 5 to adjust its spray angle according to the diameter and curvature of the steel rod, ensuring uniform cooling.

[0091] In one specific embodiment, the worm gear drive assembly includes a motor 82 and a worm 81. The motor 82 is mounted on the upper roller frame 1. The motor 82 is a stepper motor, and the worm 81 is connected to the output end of the motor 82. The worm 81 supports driving the gear teeth 41 to rotate in either the forward or reverse direction. The worm gear drive assembly also includes a bracket 83. The worm 81 driving the worm gear teeth 41 in this application can drive in both directions. The specific embodiment is prior art and will not be described in detail. The bracket 83 is disposed on the upper roller frame 1 and is used to mount the end of the worm 81 away from the motor 82. The end of the worm 81 supports rotation through the mounting hole of the bracket 83.

[0092] In one specific embodiment, the longitudinal section of the upper roller frame 1 is set in a right-angled U-shape, and the lower opening of the upper roller frame 1 is connected to the lower roller frame 2; the edges of the two side plates of the upper roller frame 1 are provided with fan-shaped grooves, and the two side plates of the air-cooled mounting plate 4 are respectively installed in the two fan-shaped grooves; the baffle 11, the air-cooled mounting plate 4, and the right-angled U-shaped upper roller frame 1 make the structure relatively sealed, ensuring the safety of operators and preventing certain high-temperature splashes.

[0093] In one specific embodiment, the lower roller frame 2 includes a first vertical plate 21, a second vertical plate 22, a third vertical plate 23, and a fourth vertical plate 24. The first vertical plate 21 and the second vertical plate 22 are arranged in right-angled trapezoids and are parallel to each other. The ends of the right-angled sides of the first vertical plate 21 and the second vertical plate 22 are connected by the third vertical plate 23. The two ends of the fourth vertical plate 24 are respectively connected to the middle of the first vertical plate 21 and the middle of the second vertical plate 22. The fourth vertical plate 24 and the third vertical plate 23 are parallel to each other. The space enclosed by the bottom of the first vertical plate 21, the second vertical plate 22, and the third vertical plate 23 is sealed by a base plate 25. The base plate 25 is provided with multiple mounting holes, and the mounting plate on the base plate 25 supports the installation of the steel rod straightening device at the target position.

[0094] In one specific embodiment, the hinge assembly includes a first shaft mounting lug 91, a second shaft mounting lug 92, and a third rotating shaft 93; two first shaft mounting lugs 91 are mounted on the side of the fourth upright plate 24 opposite to the second upright plate 22; two first shaft mounting lugs 91 are mounted on the side wall of the upper roller frame 1; two first shaft mounting lugs 91 are disposed between two second shaft mounting lugs 92; the two ends of the third rotating shaft 93 are respectively mounted in the two second shaft mounting lugs 92, and the shaft body of the third rotating shaft 93 passes through the two first shaft mounting lugs 91.

[0095] In one specific embodiment, the locking assembly includes a locking lug 101, a locking block 102, and a horizontal insert 103;

[0096] The locking lug 101 is installed on the side wall of the upper roller frame 1, and the locking block 102 is installed on the third vertical plate 23. When the upper roller frame 1 and the lower roller frame 2 are fastened together, the locking block 102 is positioned between the two locking lugs 101 and the through holes on the two locking lugs 101 are aligned. After the horizontal insert 103 is inserted into the locking lug 101, the bottom end of the locking block 102 abuts against the upper surface of the horizontal insert 103.

[0097] In one specific embodiment, two straightening rollers 3 are provided in the upper roller frame 1, and two straightening rollers 3 are provided in the lower roller frame 2; when the upper roller frame 1 and the lower roller frame 2 are fastened together, the two straightening rollers 3 in the upper roller frame 1 are positioned between the two straightening rollers 3 in the lower roller frame 2; positioning grooves a are respectively provided on the first rotating shaft 43, the third rotating shaft 93 and the rotating shaft of each straightening roller 3, each positioning groove a is perpendicular to its own axis and is located at the end, and a baffle is installed in each positioning groove a;

[0098] For each positioning slot a, one end of the baffle b is inserted into the positioning slot a;

[0099] The other end of the baffle plate b on the first rotating shaft 43 is fixed to the P-shaped side plate of the air-cooled mounting plate 4;

[0100] The other end of the baffle plate b on the straightening roller 3 inside the upper roller frame 1 is fixed on the side wall of the upper roller frame 1;

[0101] The other end of the baffle plate b on the straightening roller 3 inside the lower roller frame 2 is fixed on the side wall of the upper roller frame 1;

[0102] The other end of the baffle b on the third rotating shaft 93 is fixed to the side wall of the second shaft mounting lug 92.

[0103] A method for online correction of bending deformation of steel rods based on air cooling function, comprising the aforementioned steel rod correction device, and further comprising:

[0104] S1. Set up a steel rod straightening device at the target location, connect the blower, air compressor and flow regulating valve to the air-cooled pipe of the steel rod straightening device, and place an industrial camera and infrared thermal imager in the environment where the target location is located.

[0105] S2. Based on the recognition results from the industrial camera, the steel wire model is obtained, and the initial angle adjustment range and high-temperature area coverage are determined according to the steel wire model; specifically including:

[0106] When the steel drill type is If the diameter is 10mm × 1.5m, the initial angle adjustment range is 25° ± 5°, and the high-temperature zone covers the section from 0 to 30cm from the tip of the steel rod.

[0107] When the steel drill type is If the diameter is 20mm × 2.0m, the initial angle adjustment range is 30° ± 5°, and the high-temperature zone covers the section from 0 to 50cm from the tip of the steel rod.

[0108] When the steel drill type is If the diameter is 30mm × 2.5m, the initial angle adjustment range is 40° ± 5°, and the high-temperature zone covers the section from 0 to 60cm from the tip of the steel rod.

[0109] When the steel drill type is If the diameter is 40mm × 3.0m, the initial angle adjustment range is 50° ± 5°, and the high-temperature zone covers the section from 0 to 80cm from the tip of the steel rod.

[0110] When the steel drill type is If the diameter is 50mm × 3.5m, the initial angle adjustment range is 60° ± 5°, and the high-temperature zone covers the section from 0 to 100cm from the tip of the steel rod.

[0111] See Table 1 below for details:

[0112] Table 1

[0113]

[0114] Table 1 shows an example of the coarse adjustment parameter database. In practice, based on experimental experience and the needs of the field, those skilled in the art have a certain level of experience in controlling the coarse adjustment angle according to the type of rebar.

[0115] Coarse adjustment is a preset angle adjustment based on the steel rod model. Its purpose is to achieve initial alignment between the air-cooling module and the high-temperature area of ​​the steel rod through rapid positioning, laying the foundation for subsequent fine adjustment. The specific logic is as follows:

[0116] Triggering condition: When the steel rod is placed into the straightening channel formed by the upper and lower roller frames, the image recognition unit (industrial camera) of the furnace exit robot automatically collects the shape image of the steel rod, identifies its key parameters such as diameter and length, and completes the steel rod model matching.

[0117] Parameter Recall: The control unit (embedded PLC) calls the pre-stored "coarse adjustment parameter database" according to the matched steel rod model, as shown in Table 1 example. This database is experimentally calibrated to determine the optimal initial angle range for different steel rod models, with the angle based on the steel rod axis to ensure that the nozzle spray range covers the axial section where the high-temperature area of ​​the steel rod is concentrated.

[0118] Adjustment execution: The control unit sends commands to the drive unit (servo motor), the servo motor output shaft drives the worm gear to rotate, the worm gear meshes with the worm wheel type gear, driving the entire air-cooled mounting plate to rotate. The adjustment process uses large step sizes to quickly approach the target range.

[0119] S3. Adjust the nozzle in the steel rod straightening device to initially align with the axis of the steel rod. Based on the initial angle adjustment range, drive the air-cooled mounting plate to rotate through the worm gear drive assembly and bring the nozzle closer to the high-temperature area covered section.

[0120] S4. Based on the infrared thermal imager, the temperature distribution image of the steel rod surface is obtained, and the nozzle is aimed at the highest point of the steel rod surface temperature by driving the worm gear drive assembly.

[0121] Steps S3 to S4 involve fine-tuning the angle. This fine-tuning is based on dynamic compensation adjustment using real-time image recognition. The aim is to achieve perfect alignment between the air-cooling module and the highest temperature area of ​​the steel rod through precise positioning, thereby improving cooling efficiency. The specific logic is as follows:

[0122] Triggering conditions: After coarse adjustment, the infrared thermal imager in the image recognition unit is activated to collect temperature distribution images on the surface of the steel rod, focusing on identifying high-temperature areas with temperatures ≥300℃, especially the highest temperature point (usually the part with the most severe deformation).

[0123] Deviation calculation: The control unit processes the temperature image through a fine-tuning algorithm: locates the coordinates of the highest temperature point (radial offset with the steel rod axis as the origin); and calculates the angular deviation between this point and the current air-cooled module nozzle spray center.

[0124] Adjustment execution: The control unit sends fine-tuning commands to the servo motor based on the deviation value, driving the worm gear structure to rotate the air-cooling module within a small range. The adjustment uses small-step gradual compensation to ensure that the highest temperature point falls completely within the nozzle spray range.

[0125] The specific fine-tuning algorithm within the fine adjustment is based on existing technology. After obtaining the offset from the infrared thermal imager, it makes precise small-range adjustments to ensure that the highest point falls completely within the nozzle spray range.

[0126] S5. Adjust the flow rate and pressure in the air-cooled pipe through the flow regulating valve, and cool the highest point of the steel rod surface through the nozzle. Repeat S3 until the temperature of the highest point of the steel rod surface is less than 200°.

[0127] This device integrates online cooling and straightening: A wind-cooling module provides real-time cooling to the high-temperature steel rod, reducing its temperature and extending its service life. Quick-change structure: The openable design of the upper and lower roller frames, combined with a wedge-shaped block connection, allows for rapid rod replacement, improving operational efficiency. Multi-angle adjustable cooling system: The nozzles are adjustable at multiple angles via a flexible adjustment mechanism, allowing for adjustments to the cooling angle based on the rod's diameter and curvature, ensuring uniform cooling. High-temperature and wear-resistant design: The high-temperature and wear-resistant layer on the straightening roller surface can withstand temperatures above 300℃, effectively extending the roller's service life and reducing maintenance costs. Safety protection structure: The U-shaped design (top cap) of the upper roller frame effectively blocks splashes and heat radiation from the furnace, protecting equipment and operators. This invention uses coarse and fine angle adjustments to target the highest temperature zone, and then sequentially cools the rod according to its temperature, preventing deformation.

[0128] The following points need to be explained:

[0129] (1) The accompanying drawings of the embodiments of the present invention only involve the structures involved in the embodiments of the present invention. Other structures can refer to the general design.

[0130] (2) For clarity, the thickness of layers or regions is enlarged or reduced in the drawings used to describe embodiments of the invention, i.e., these drawings are not drawn to scale. It is understood that when an element such as a layer, film, region or substrate is referred to as being “above” or “below” another element, the element may be “directly” located “above” or “below” the other element or there may be intermediate elements.

[0131] (3) Where there is no conflict, the embodiments of the present invention and the features in the embodiments can be combined with each other to obtain new embodiments.

[0132] The above are merely specific embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. The scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for online correction of bending deformation of steel bars based on air cooling, characterized in that, This includes an online straightening device for bending deformation of steel bars based on air cooling, the device comprising: The upper roller frame and the lower roller frame are rotatably connected to achieve opening and closing; A straightening roller, wherein at least one straightening roller is installed in the upper roller frame and at least one straightening roller is installed in the lower roller frame; The air-cooled mounting plate is integrally formed and U-shaped. The two parallel side plates of the air-cooled mounting plate are P-shaped. An air-cooled pipe is provided on the middle plate inside the air-cooled mounting plate for connecting the two side plates. The two side plates of the air-cooled mounting plate are mounted on the two side walls of the upper roller frame through a first rotating shaft. The middle plate of the air-cooled mounting plate blocks the top end of the upper roller frame. A worm gear drive assembly is mounted on the upper roller frame. The arc-shaped edge of one side plate of the air-cooled mounting plate is provided with worm gear teeth, which support meshing with the worm inside the worm gear drive assembly. Nozzles are connected to the outlet of each air-cooled duct. The nozzles are mounted on the air-cooled mounting plate via an angle adjustment assembly, and the angle of the nozzles can be adjusted up and down. The worm gear drive assembly adjusts the overall rotation angle of the air-cooled mounting plate by rotating the meshing side plate. The air-cooled duct includes: a main duct and branch ducts; The main pipe is L-shaped and is installed on the back of the middle plate of the air-cooled mounting plate; The branch pipes are distributed on both sides of the main pipe and are connected to the main pipe, and the multiple branch pipes are arranged in a concentric arc shape; The air-cooled mounting plate is provided with multiple through holes, and each branch pipe is connected to the nozzle through the corresponding through hole; The angle adjustment assembly includes: a mounting ear, a nozzle base, a second rotating shaft, and a spring; Mounting ears are installed on both sides of each through hole, and a nozzle base is provided between the mounting ears on both sides of each through hole. The nozzle base is installed between the mounting ears via a second rotating shaft. The nozzle base is provided with a meshing tooth on one side, and the meshing tooth of the nozzle base is supported in meshing with the meshing tooth on the mounting ear on the same side; A spring end fixing groove is provided on the other side of the nozzle base. A spring end fixing groove is provided on the mounting ear of the nozzle base opposite to the meshing teeth. The spring is sleeved on the second rotating shaft and its two ends are respectively installed in the spring end fixing groove of the nozzle base and the spring end fixing groove of the mounting ear on the same side. The nozzle base is provided with a through port communicating with the nozzle, and the nozzle is mounted on the nozzle base; When the rotation direction of the nozzle is adjusted up and down, the nozzle base is driven to press against the spring, causing the meshing teeth of the nozzle base to separate from the meshing teeth on the mounting ear. The nozzle base is rotated up and down to rotate to the target angle, and the meshing teeth on the nozzle base are driven to engage with the meshing teeth on the mounting ear, so that the nozzle base stays at the target angle position. The method includes: S1. Set up a steel rod straightening device at the target location, connect the blower, air compressor and flow regulating valve to the air-cooled pipe of the steel rod straightening device, and place an industrial camera and infrared thermal imager in the environment where the target location is located. S2. Based on the recognition results of the industrial camera, the steel wire model is obtained, and the initial angle adjustment range and the high-temperature area coverage section are obtained according to the steel wire model. S3. Adjust the nozzle in the steel rod straightening device to initially align with the axis of the steel rod. Based on the initial angle adjustment range, drive the air-cooled mounting plate to rotate through the worm gear drive assembly and bring the nozzle closer to the high-temperature area covered section. S4. Based on the infrared thermal imager, the temperature distribution image of the steel rod surface is obtained, and the nozzle is aimed at the highest point of the steel rod surface temperature by driving the worm gear drive assembly. S5. Adjust the flow rate and pressure in the air-cooled pipe through the flow regulating valve, and cool the highest point of the steel rod surface through the nozzle. Repeat S3 until the temperature of the highest point of the steel rod surface is less than 200℃.

2. The online correction method for bending deformation of steel bars based on air cooling function according to claim 1, characterized in that, The worm gear drive assembly includes: a motor and a worm gear; The motor is mounted on the upper roller frame; The worm gear is connected to the output end of the motor; The worm gear supports driving the gear teeth to rotate in the forward or reverse direction. The worm gear drive assembly also includes a bracket; The bracket is mounted on the upper roller frame and is used to mount the end of the worm gear away from the motor. The end of the worm gear is supported to rotate in the mounting hole of the bracket.

3. The online correction method for bending deformation of steel bars based on air cooling function according to claim 2, characterized in that, The upper roller frame has a right-angled U-shaped longitudinal section, and the lower opening of the upper roller frame is connected to the lower roller frame; the edges of the two opposite side plates of the upper roller frame are provided with fan-shaped grooves, and the two side plates of the air-cooled mounting plate are respectively installed in the two fan-shaped grooves; The lower roller frame includes a first vertical plate, a second vertical plate, a third vertical plate, and a fourth vertical plate; The first upright plate and the second upright plate are arranged in right-angled trapezoids, and the first upright plate and the second upright plate are arranged in parallel. The ends of the right-angled sides of the first upright plate and the second upright plate are connected by a third upright plate. The two ends of the fourth upright plate are respectively connected to the middle of the first upright plate and the middle of the second upright plate, and the fourth upright plate and the third upright plate are arranged in parallel. The space enclosed by the bottom of the first upright plate, the second upright plate, and the third upright plate is sealed by the bottom plate.

4. The online correction method for bending deformation of steel bars based on air cooling function according to claim 3, characterized in that, It also includes hinge components and locking components; The hinge assembly includes a first axis mounting lug, a second axis mounting lug, and a third rotating shaft; Two first shaft mounting lugs are mounted on the side of the fourth upright plate opposite to the second upright plate; Two first shaft mounting lugs are mounted on the side wall of the upper roller frame; Two first shaft mounting lugs are positioned between two second shaft mounting lugs; The two ends of the third rotating shaft are respectively installed in two second shaft mounting ears, and the shaft body of the third rotating shaft passes through two first shaft mounting ears; The locking assembly includes a locking lug, a locking block, and a transverse insert; The locking lugs are installed on the side wall of the upper roller frame, and the locking block is installed on the third vertical plate. When the upper roller frame and the lower roller frame are fastened together, the locking block is positioned between the two locking lugs and the through holes on the two locking lugs are aligned. After the locking lugs are inserted horizontally, the bottom end of the locking block abuts against the upper surface of the horizontal insertion.

5. The online correction method for bending deformation of steel bars based on air cooling function according to claim 4, characterized in that, Two straightening rollers are provided in the upper roller frame, and two straightening rollers are provided in the lower roller frame; When the upper roller frame and the lower roller frame are engaged, the two straightening rollers inside the upper roller frame are positioned between the two straightening rollers of the lower roller frame. Positioning grooves are provided on the first rotating shaft, the third rotating shaft and the rotating shaft of each straightening roller. Each positioning groove is perpendicular to its own axis and is located at the end. A baffle is installed in each positioning groove. For each positioning slot, one end of the baffle is inserted into the positioning slot; The other end of the baffle on the first rotating shaft is fixed to the P-shaped side plate of the air-cooled mounting plate; The other end of the baffle on the straightening roller inside the upper roller frame is fixed to the side wall of the upper roller frame; The other end of the baffle on the straightening roller inside the lower roller frame is fixed to the side wall of the lower roller frame; The other end of the baffle on the third rotating shaft is fixed to the side wall of the second shaft mounting lug; Each straightening roll has a metal-ceramic coating, a weld overlay alloy layer, or a thermally sprayed alloy layer on its outer surface.

6. The online correction method for bending deformation of steel bars based on air cooling function according to claim 5, characterized in that, The identification result based on the industrial camera in S2 yields the steel wire model, and the initial angle adjustment range and high-temperature area coverage section are obtained based on the steel wire model: When the steel drill type is If the diameter is 10mm × 1.5m, the initial angle adjustment range is 25° ± 5°, and the high-temperature zone covers the section from 0 to 30cm from the tip of the steel rod. When the steel drill type is If the diameter is 20mm × 2.0m, the initial angle adjustment range is 30° ± 5°, and the high-temperature zone covers the section from 0 to 50cm from the tip of the steel rod. When the steel drill type is If the diameter is 30mm × 2.5m, the initial angle adjustment range is 40° ± 5°, and the high-temperature zone covers the section from 0 to 60cm from the tip of the steel rod. When the steel drill type is If the diameter is 40mm × 3.0m, the initial angle adjustment range is 50° ± 5°, and the high-temperature zone covers the section from 0 to 80cm from the tip of the steel rod. When the steel drill type is If the diameter is 50mm × 3.5m, the initial angle adjustment range is 60° ± 5°, and the high-temperature zone covers the section from 0 to 100cm from the tip of the steel rod.

7. The online correction method for bending deformation of steel bars based on air cooling function according to claim 6, characterized in that, The number of nozzles is 15.

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