A deep-space feeding and welding device and method for irregularly shaped steel cages

Abstract

This invention relates to the field of welding technology for irregularly shaped steel cages, and discloses a device and method for feeding and welding irregularly shaped steel cages in deep spaces. It aims to solve the technical problem that feeding and welding steel bars in the deep, narrow spaces of irregularly shaped steel cages is extremely difficult in existing technologies. The invention includes a steel bar storage area and a steel bar welding area. The steel bar storage area includes a wire feeding frame, a straightening mechanism next to the wire feeding frame, and a steel bar placement platform next to the straightening mechanism. The steel bar placement platform is mounted on a base and slides linearly along a base moving track. A welding frame moving track is mounted on the base to support the welding frame and allow it to move linearly along the base. The irregularly shaped steel cage to be welded is placed at the center of the welding area. A support frame is placed on one side of the irregularly shaped steel cage, corresponding to the welding frame, and is movably mounted on the support frame moving track. This invention achieves automatic feeding, precise positioning, and welding of steel bars in the deep, narrow spaces of irregularly shaped steel cages.

Description

Technical Field

[0001] This invention relates to the field of welding technology for irregularly shaped steel cages, and in particular to a welding device and method for deep-space feeding of irregularly shaped steel cages. Background Technology

[0002] In tunnel and underground engineering construction, the invert block, as a crucial component of the tunnel structure, directly impacts the stability and durability of the tunnel through the welding quality of its reinforcing cage. Traditional invert block reinforcing cage welding is largely manual. Multi-layered reinforcing cages require multiple layers of manual welding during the manual process. Welding of diagonal bars, herringbone bars, and curved bars all involve manual, layer-by-layer welding. Furthermore, manual welding is highly susceptible to variations in worker skill level and working conditions, resulting in inconsistent welding quality. Manually welded joints are prone to cracking and detachment, leading to a decrease in the structural strength of the invert block and posing serious safety hazards. In addition, existing reinforcing cage processing equipment is mostly designed for conventionally shaped reinforcing cages. When handling irregularly shaped reinforcing cages like invert blocks, it is difficult to achieve automated feeding, precise positioning, and efficient welding of the main reinforcing bars, failing to meet the high-quality, high-efficiency fabrication requirements of tunnel engineering for invert block reinforcing cages.

[0003] Chinese patent document 202510571279.7 discloses a steel cage welding device, comprising: a welding frame, a support frame for supporting longitudinal bars arranged sequentially on the welding frame, and a traction frame for pulling longitudinal bars; an installation mechanism for installing longitudinal bars on the support frame; and a pushing mechanism for pushing longitudinal bars on the support frame to the traction frame; wherein the support frame is composed of an installation frame and a rotating disk; the installation frame is fixedly connected to the welding frame; and the rotating disk is rotatably installed on the installation frame.

[0004] However, the above-mentioned solutions suffer from at least the following technical problems during implementation: It is extremely difficult to perform steel bar loading and welding operations in the deep, narrow spaces within irregularly shaped, non-standard cylindrical steel cages. This results in high risks associated with manual operation, difficulty in guaranteeing accuracy, and low efficiency. Therefore, there is an urgent need to propose a device and method for loading and welding steel bars in the deep spaces of irregularly shaped steel cages. Summary of the Invention

[0005] In view of the above technical problems, this disclosure provides a device and method for feeding and welding steel bars in the deep space of irregularly shaped steel cages, which solves the problem that it is extremely difficult to carry out steel bar feeding and welding operations in the deep and narrow space of irregularly shaped and non-standard cylindrical steel cages in the prior art. This addresses the technical problems of high risk of manual operation, difficulty in guaranteeing accuracy, and low efficiency.

[0006] According to one aspect of this disclosure, a deep-space feeding and welding device and method for irregularly shaped steel cages is provided, comprising a steel bar storage area and a steel bar welding area. The steel bar storage area includes a wire feeding frame for rotating under traction to transport steel bars. A straightening mechanism is provided next to the wire feeding frame for straightening the steel bars transported by the wire feeding frame to facilitate steel bar forming. A steel bar placement platform is provided next to the straightening mechanism for flat placement of the steel bars. The steel bar placement platform is disposed on a base for sliding along a straight line on a base moving track. A welding frame moving track is provided on the base to support the welding frame for linear movement on the base, for the welding frame to slide into and out of the steel bar welding area. A non-standard steel cage to be welded is set at the center of the steel bar welding area. A support frame is set on one side of the non-standard steel cage, corresponding to the welding frame. The support frame is movably installed on the support frame moving track so that the support frame can extend into and out of the non-standard steel cage and move along the extension direction of the steel cage.

[0007] In some embodiments of this disclosure, the welding frame includes a support column, a welding beam is provided on one side of the support column, and multiple welding heads and upper rib components are arrayed on the bottom surface of the welding beam.

[0008] In some embodiments of this disclosure, a rotator is provided above the support column to drive the welding beam to rotate around the column, thereby moving the reinforcing bars from the reinforcing bar storage area to the reinforcing bar welding area.

[0009] In some embodiments of this disclosure, a lower limiter is provided below the column to limit the falling of the reinforcing bar.

[0010] In some embodiments of this disclosure, the upper rib component includes a J-shaped gripping component or a magnet.

[0011] In some embodiments of this disclosure, the wire feeding frame includes a base, on which a support tray is mounted via a bearing assembly, and a rotating shaft is mounted above the bearing assembly.

[0012] In some embodiments of this disclosure, the wire feeding frame further includes a lifting ring disposed above the rotating shaft to facilitate overall movement of the wire feeding frame.

[0013] In some embodiments of this disclosure, the straightening mechanism includes a plurality of staggered straightening wheels for continuously straightening reinforcing bars, wherein the straightening wheels are provided with grooves to accommodate the passage of the reinforcing bars.

[0014] In some embodiments of this disclosure, the straightening wheel is equipped with a movable component for adjusting the distance between the upper and lower straightening wheels, and the movable component includes a lead screw lifting component.

[0015] A method for deep-space feeding and welding of irregularly shaped steel cages, applicable to a deep-space feeding and welding device for irregularly shaped steel cages, includes the following steps: (1) Loading: The steel bars are drawn out from the wire feeding frame in the steel bar storage area, straightened by the straightening mechanism, and then transported to the steel bar placement platform; (2) Rebar removal: drive the base and the welding frame on it to move so that the welding frame is above the rebar; the rebar is fixed by adsorbing the upper rebar component, and the welding beam is driven to rotate by the rotator to lift the rebar away from the rebar placement platform 3; (3) Feeding: Drive the base to move along the base moving track and drive the welding frame to move along the welding frame moving track, sending the welding frame and the steel bars it adsorbs into the predetermined welding position inside the irregular steel cage; at the same time, drive the support frame to move along the support frame moving track to the inside of the irregular steel cage and set opposite to the welding frame. (4) Welding: Control the multiple welding heads on the welding beam to work independently, cooperate with the support frame, and weld the intersection of the steel bars and the steel cage.

[0016] The beneficial effects of this invention are as follows: It enables efficient operation in deep spaces. Through the coordinated operation of the movable welding frame and the support frame, it realizes the automatic feeding, precise positioning and welding of steel bars in the narrow space of the deep space of the irregular steel cage, and solves the technical problems of traditional manual operation that is difficult to enter deep spaces, high labor intensity and low efficiency.

[0017] The welding quality and consistency have been improved. Multiple welding heads arranged in an array on the bottom surface of the welded beam can work independently. Combined with the stable support of the support frame, the welding process at the intersection of the steel bars and the steel cage is stable and reliable, effectively improving the uniformity and consistency of the welding quality.

[0018] With excellent flexibility and adaptability, the welding frame can drive the welding beam to rotate through the rotator, realizing flexible transfer of steel bars from the storage area to the welding area; the spacing of the straightening wheels in the straightening mechanism is adjustable, which can adapt to the processing needs of steel bars of different specifications, enabling the device to cope with a variety of complex working conditions.

[0019] The process flow and operational safety have been optimized, forming an integrated continuous process from rebar layout and alignment to material loading and welding. This reduces intermediate hoisting and manual intervention, lowers safety risks, and improves overall operational efficiency and reliability. The mobile track design ensures precise and controllable material loading and welding positions, good overall coordination, and easy on-site deployment and application, demonstrating strong engineering practical value. Attached Figure Description

[0020] Figure 1 A schematic diagram of a deep-space feeding and welding device for irregularly shaped steel cages; Figure 2 for Figure 1 Enlarged view of the structure of section A in the middle; The components in the diagram are named as follows: 1. Wire laying frame; 2. Straightening mechanism; 3. Rebar placement platform; 4. Base; 5. Base moving track; 6. Welding frame moving track; 7. Welding frame; 8. Irregular rebar cage; 9. Support frame; 10. Support frame moving track; 11. Welding beam; 12. Welding head; 13. Upper reinforcement component; 14. Rotator; 15. Lower limit device; 16. Base; 17. Bearing assembly; 18. Loading tray; 19. Rotating shaft; 20. Lifting ring; 21. Straightening wheel; 22. Moving component; 23. J-shaped gripping component. Detailed Implementation

[0021] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention. Example 1

[0022] This example discloses a deep-space feeding and welding device and method for irregularly shaped steel reinforcement cages. (See also...) Figures 1 to 2 The system includes a rebar storage area and a rebar welding area. The rebar storage area includes a wire feeding frame 1, which rotates under traction to transport rebars. A straightening mechanism 2 is provided next to the wire feeding frame 1 to straighten the rebars transported by the wire feeding frame 1 so as to facilitate rebar forming. A rebar placement platform 3 is provided next to the straightening mechanism 2 to place the rebars flat. The rebar placement platform 3 is set on a base 4 to slide in a straight line on a base moving track 5. A welding frame moving track 6 is provided on the base 4 to support the welding frame 7 to move in a straight line on the base 4, so that the welding frame 7 can slide into and out of the rebar welding area. A non-standard steel cage 8 to be welded is set in the center of the steel bar welding area. A support frame 9 is set on one side of the non-standard steel cage 8, corresponding to the welding frame 7. The support frame 9 is movably installed on the support frame moving track 10 so that the support frame 9 can extend into and out of the non-standard steel cage 8 and move along the extension direction of the steel cage.

[0023] The welding frame 7 includes a support column, a welding beam 11 is provided on one side of the support column, and multiple welding heads 12 and upper rib components 13 are arranged in an array on the bottom surface of the welding beam 11.

[0024] A rotator 14 is installed above the support column to drive the welded beam 11 to rotate around the column, thereby moving the reinforcing bars from the reinforcing bar storage area to the reinforcing bar welding area.

[0025] A lower limit device 15 is installed below the column to limit the falling of the reinforcing bars.

[0026] The upper rib component 13 includes a J-shaped gripping component 23 or a magnet.

[0027] The wire feeding frame 1 includes a base 16, on which a bearing tray 18 is mounted via a bearing assembly 17, and a rotating shaft 19 is mounted above the bearing assembly 17.

[0028] The wire feeding frame 1 also includes a lifting ring 20 disposed above the rotating shaft 19 to facilitate the overall movement of the wire feeding frame 1.

[0029] The straightening mechanism 2 includes multiple staggered straightening wheels 21 for continuously straightening reinforcing bars. The straightening wheels 21 are provided with grooves to accommodate the passage of reinforcing bars.

[0030] The straightening wheel 21 is equipped with a moving component 22 for adjusting the distance between the upper and lower straightening wheels. The moving component 22 includes a lead screw lifting component.

[0031] A method for deep-space feeding and welding of irregularly shaped steel cages, applicable to a deep-space feeding and welding device for irregularly shaped steel cages, includes the following steps: (1) Loading: The steel bars are drawn out from the wire feeding frame in the steel bar storage area, straightened by the straightening mechanism, and then transported to the steel bar placement platform; (2) Rebar removal: drive the base and the welding frame on it to move so that the welding frame is above the rebar; the rebar is fixed by adsorbing the upper rebar component, and the welding beam is driven to rotate by the rotator to lift the rebar away from the rebar placement platform 3; (3) Feeding: Drive the base to move along the base moving track and drive the welding frame to move along the welding frame moving track, sending the welding frame and the steel bars it adsorbs into the predetermined welding position inside the irregular steel cage; at the same time, drive the support frame to move along the support frame moving track to the inside of the irregular steel cage and set opposite to the welding frame. (4) Welding: Control the multiple welding heads on the welding beam to work independently, cooperate with the support frame, and weld the intersection of the steel bars and the steel cage.

[0032] Although some preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including the preferred embodiments as well as all changes and modifications falling within the scope of the invention.

[0033] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this application and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A deep-space feeding and welding device for irregularly shaped steel cages, characterized in that: The system includes a rebar storage area and a rebar welding area. The rebar storage area includes a wire feeding frame that rotates under traction to transport rebars. A straightening mechanism is installed next to the wire feeding frame to straighten the rebars transported by the wire feeding frame, facilitating rebar forming. A rebar placement platform is installed next to the straightening mechanism to place the rebars flat. The rebar placement platform is mounted on a base, which moves along a base moving track. A welding frame moving track is installed on the base to support the welding frame and allow it to move linearly along the base, enabling the welding frame to slide into and out of the rebar welding area. A special-shaped steel cage to be welded is set at the center of the steel bar welding area. A support frame is set on one side of the special-shaped steel cage, corresponding to the welding frame. The support frame is movably installed on the support frame moving track so that the support frame can extend into and out of the special-shaped steel cage and move along the extension direction of the steel cage. The welding frame includes a support column, a welding beam is provided on one side of the support column, and multiple welding heads and upper rib components are arrayed on the bottom surface of the welding beam. A rotator is installed above the support column to drive the welded beam to rotate around the column, thereby moving the reinforcing bars from the reinforcing bar storage area to the reinforcing bar welding area.

2. The special-shaped reinforcement cage deep space loading and welding device according to claim 1, characterized in that: A lower limiter is installed below the column to restrict the falling of the reinforcing bars.

3. The deep-space feeding and welding device for irregularly shaped steel cages as described in claim 1, characterized in that: The upper rib component includes a J-shaped gripping component or a magnet.

4. The deep-space feeding and welding device for irregularly shaped steel cages as described in claim 1, characterized in that: The wire feeding frame includes a base, on which a bearing tray is mounted via a bearing assembly, and a rotating shaft is mounted above the bearing assembly.

5. The deep-space feeding and welding device for irregularly shaped steel cages as described in claim 4, characterized in that: The wire feeding frame also includes a lifting ring located above the rotating shaft to facilitate the overall movement of the wire feeding frame.

6. The deep-space feeding and welding device for irregularly shaped steel cages as described in claim 1, characterized in that: The straightening mechanism includes multiple staggered straightening wheels for continuously straightening reinforcing bars, and the straightening wheels are provided with grooves to accommodate the passage of the reinforcing bars.

7. The deep-space feeding and welding device for irregularly shaped steel cages as described in claim 6, characterized in that: The straightening wheel is equipped with a movable component for adjusting the distance between the upper and lower straightening wheels. The movable component includes a lead screw lifting component.

8. A method for deep-space feeding and welding of irregularly shaped steel cages, applicable to the deep-space feeding and welding device for irregularly shaped steel cages as described in any one of claims 1 to 7, characterized in that, Includes the following steps: (1) Loading: The steel bars are drawn out from the wire feeding frame in the steel bar storage area, straightened by the straightening mechanism, and then transported to the steel bar placement platform; (2) Rebar removal: The drive base and the welding frame on it move to position the welding frame above the reinforcing bar; the reinforcing bar is fixed by adsorbing the upper reinforcing bar component, and the welding beam is driven to rotate by the rotator to lift the reinforcing bar off the reinforcing bar placement platform; (3) Feeding: Drive the base to move along the base moving track and drive the welding frame to move along the welding frame moving track, sending the welding frame and the steel bars it adsorbs into the predetermined welding position inside the irregular steel cage; at the same time, drive the support frame to move along the support frame moving track to the inside of the irregular steel cage and set opposite to the welding frame. (4) Welding: Control the multiple welding heads on the welding beam to work independently, cooperate with the support frame, and weld the intersection of the steel bars and the steel cage.

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