Steel bar vibration feeding mechanism and intelligent steel bar vibration feeding system

Abstract

The invention relates to the technical field of steel bar vibration feeding, in particular to a steel bar vibration feeding mechanism and an intelligent steel bar vibration feeding system.The steel bar vibration feeding mechanism comprises a plurality of material dispersing units arranged at intervals, and feeding conveying units are arranged between every two adjacent material dispersing units and on the outer side of the material dispersing unit on the outermost edge correspondingly; the bottoms of the material dispersing units and the bottoms of the feeding and conveying units are fixed to the ground. The material dispersing unit comprises a first rack, the bottom of the first rack is fixedly arranged, vibration scattering devices are installed at the four corners of the top of the first rack respectively, a rib separating mechanism is installed in the middle space of the vibration scattering devices, and the bottom of the rib separating mechanism is installed at the top of the first rack; the vibration scattering device comprises a plurality of vibrators fixedly installed at the four corners of the top of the first rack, and a vibration rack is installed at the top of each vibrator. According to the invention, the processes of scattering, separating, supporting and translating and conveying reinforcing steel bars are sequentially completed in the production process.

Description

Technical Field

[0001] This invention relates to the field of rebar vibration feeding technology, and in particular to a rebar vibration feeding mechanism and a rebar intelligent vibration feeding system. Background Technology

[0002] Traditional steel bar loading relies heavily on manual labor or simple mechanical handling, requiring manual placement of bundles of steel bars one by one into the feed inlet of the processing equipment. This method is labor-intensive, costly, and inefficient, making it difficult to match the cycle time of automated equipment. Furthermore, the placement posture of the steel bars is difficult to control, easily leading to deviations and stacking, resulting in subsequent dimensional deviations in processing, equipment jamming, and other problems, affecting quality and safety.

[0003] To address the aforementioned deficiencies, various automatic feeding systems exist in the prior art. For example, the automatic steel bar feeding system disclosed in patent CN202121920072.X includes a vibrating sorting and separating platform and a stepped feeding platform. The latter is installed at one end of the former and its height is no higher than that of the former. The vibrating sorting and separating platform is responsible for lifting and separating multiple steel bars, while the stepped feeding platform achieves the lifting of steel bars one by one through a fixed bed, a movable bed, and a power source.

[0004] As can be seen from the above description, it has the following drawbacks when used:

[0005] First, during vibration separation, the reinforcing bars are prone to deviating from their path due to inertia, getting stuck and stacked at the joints, disrupting the continuity of material feeding and requiring manual intervention; moreover, they have poor adaptability to the length of the reinforcing bars, and their stability decreases when handling excessively long or short reinforcing bars, making them prone to falling off.

[0006] Secondly, the power transmission and lifting accuracy of the stepped feeding platform are insufficient. Its lifting structure, which combines the fixed and movable beds, lacks an adaptive adjustment mechanism, making it unable to meet the lifting requirements of rebars with different diameters. Based on long-term field experience, rebars with diameters below 20 mm are thin, soft, easily tangled, and difficult to separate. The stepped feeding system cannot properly handle rebars with diameters below 20 mm, which is a major challenge in the industry. Furthermore, when the diameter changes significantly, manual disassembly and adjustment are required, which is cumbersome and inaccurate. The movable bed's lifting is prone to jamming or speed fluctuations, leading to rebar posture imbalance, affecting subsequent feeding positioning accuracy, and increasing the risk of processing errors.

[0007] Therefore, designing a rebar vibration feeding mechanism and intelligent system that can achieve precise connection, adapt to different specifications of rebar, and provide stable feeding is of great practical significance and application value. Summary of the Invention

[0008] To solve one of the aforementioned technical problems, the present invention adopts the following technical solution: a rebar vibratory feeding mechanism, comprising a plurality of spaced bulk material units, with feeding and conveying units respectively arranged between adjacent bulk material units and on the outer side of the outermost bulk material unit; the bottoms of each bulk material unit and each feeding and conveying unit are fixed to the ground; each bulk material unit includes a first frame, the bottom of which is fixedly installed; a vibratory breaker is installed at each of the four corners of the top of the first frame; a rebar separating mechanism is installed in the central space of the vibratory breaker, the bottom of which is installed on the top of the first frame; the vibratory breaker includes a plurality of vibrators fixedly installed at the four corners of the top of the first frame, and a vibratory frame is installed on the top of each vibrator.

[0009] Based on any of the above technical solutions, a further optimization is made as follows: the rib-splitting mechanism includes a rib-splitting lifting cylinder fixedly installed on the top of the first frame, the top of the rib-splitting lifting cylinder extending into the corresponding space of the vibrating frame, and a rib-splitting device fixedly installed on the top of the telescopic end of the rib-splitting lifting cylinder.

[0010] Based on any of the above technical solutions, a further optimization is made as follows: the reinforcing bar separator includes a conical lifting device fixedly installed on the top of the piston rod of the reinforcing bar lifting cylinder. The conical lifting device is used to follow the lifting and lowering of the reinforcing bar lifting cylinder and separate adjacent reinforcing bars by lifting them upwards and flattening them on the top of the vibrating machine frame.

[0011] Based on any of the above technical solutions, a further optimization is made as follows: pre-reinforcement components are installed on the top sides of the first frame on both sides of the conical jack. The pre-reinforcement components include pulse air nozzles fixedly installed on the top of the first frame. The outlet end of the pulse air nozzle is oriented and used to blow away adjacent steel bars.

[0012] The tilt angle of each pulse air nozzle can be adjusted as needed along the direction of the steel bar spacing.

[0013] Each of the pulse nozzles is connected to an external air source via a hose. A rotary motor is fixedly installed on a frame on one side of each pulse nozzle. The motor shaft of the rotary motor is fixed to the outer side wall of the pulse nozzle by a clamp. When the rotary motor rotates, it drives the pulse nozzle to adjust the tilt angle along the front-back direction.

[0014] Based on any of the above technical solutions, a further optimization is made by welding a number of first retaining plates at intervals along the length of the reinforcing bars on the top front side of the vibrating frame. The first retaining plates are used to prevent the reinforcing bars from slipping backward when following the vibration.

[0015] Based on any of the above technical solutions, a further optimization is made as follows: the feeding and conveying unit includes a guide walking frame fixed on the ground, a walking mechanism for translating along the direction of the steel bar spacing is provided above the guide walking frame, and a steel bar translating and conveying mechanism is installed above the walking mechanism. The steel bar translating and conveying mechanism is used to support and convey each steel bar to be conveyed to the downstream workstation; the steel bar translating and conveying mechanism is driven by a matching power component.

[0016] Based on any of the above technical solutions, a further optimization is made as follows: the rebar translation and conveying mechanism is connected to the traveling mechanism through a lifting mechanism; the lifting mechanism includes two lifting cylinder groups spaced apart on both sides of the top of the traveling mechanism, the two lifting cylinder groups move up and down synchronously during operation and have a locking function, the bottom of each lifting cylinder group is fixed to the top of the traveling mechanism, and the top of each lifting cylinder group is fixed to the bottom of the rebar translation and conveying mechanism, the lifting mechanism drives the rebar translation and conveying mechanism and the rebars on it to move up and down through its own lifting and down and match the height of different downstream work positions.

[0017] Based on any of the above technical solutions, a further optimization is made as follows: the walking mechanism includes a walking frame disposed on the top of the guide walking frame, walking wheels are movably installed at the four corners of the bottom of the walking frame, the bottom of each walking wheel movably abuts against the guide plane at the top, and limiting wheel seats that abut against the corresponding sides of the guide walking frame are fixed at the four corners of the walking frame, and the axle of each walking wheel is movably inserted into the corresponding shaft hole of the limiting wheel seat, and a translation driver is installed in the middle of the walking frame.

[0018] Based on any of the above technical solutions, a further optimization is made as follows: the translational driver includes a rack fixed to the top of the middle section of the guide walking frame and arranged along its length direction, a horizontally arranged drive gear meshing on one side of the rack, the drive gear fixing the output end of the walking drive motor with a reducer above it, and the walking drive motor being fixed as a whole on the walking frame.

[0019] Based on any of the above technical solutions, the following further optimization is made: the steel bar translation and conveying mechanism includes a lifting storage rack fixed on the top of the lifting mechanism and arranged along the conveying direction of the steel bar, chain drive assemblies are symmetrically installed on the two side walls of the lifting storage rack, and the rear ends of the two chain drive assemblies are connected through a drive shaft, which is driven by an externally matched power component.

[0020] The drive shafts on each of the steel bar translation and conveying mechanisms operate synchronously and realize step-by-step feeding of the steel bars to be conveyed.

[0021] The chain drive assembly includes two driven sprockets respectively inserted into the front side wall of the lifting storage rack. Drive sprockets are respectively spaced apart on the rear side of each driven sprocket. Each drive sprocket is coaxially fixed to the end of the transmission main shaft. The driven sprockets and the drive sprockets on the same side are connected by a transmission chain. The top of each transmission chain is used to support the reinforcing bars.

[0022] Based on any of the above technical solutions, a further optimization is made as follows: a steel bar baffle is fixedly connected to the end of each of the transmission main shafts. The steel bar baffle is vertically set in the normal state and is used to block and limit the steel bars upstream of it. When the steel bar baffle rotates with the transmission main shaft, its free end can push the current steel bar downstream. Each of the steel bar baffles is in a synchronous operation state when working and does not interfere with the movement of other parts when rotating in the circumferential direction.

[0023] The present invention also provides a rebar intelligent vibration feeding system, including the rebar vibration feeding mechanism as described above, and a downstream processing station is provided downstream of the rebar vibration feeding mechanism.

[0024] The present invention also provides a method for intelligent vibration feeding of reinforcing bars using the above-mentioned equipment, comprising the following steps:

[0025] S1. Bundles of steel bars are hoisted to the top of the bulk material unit, aligned and positioned, and then unbundled.

[0026] S2. Start the bulk material unit to vibrate and disperse the material and divide it into intermittent sections. Adjust the frequency of the vibrator according to the preset steel bar specifications. The steel bar lifting cylinder drives the conical lifting device to rise and fall intermittently, and cooperates with the pulse air nozzle to periodically spray air to complete the steel bar dispersing, initial steel bar division and flattening.

[0027] S3. The controller collects flat images through the matching visual sensor, analyzes whether the spacing of the steel bars in the image meets the standard and whether there is any stacking or entanglement. If it does not meet the standard, the controller adjusts the tilt angle of the corresponding pulse air nozzle, the jet intensity and the lifting cylinder amplitude accordingly, and then performs a second calibration until it meets the standard.

[0028] S4. The controller controls the movement of the walking mechanism based on the rebar laying range fed back by the visual sensor. When the mechanism moves to the docking position, the positioning switch is triggered to achieve precise positioning. The lifting cylinder group drives the conveying mechanism to rise to the same height as the vibrating machine frame and then locks.

[0029] S5. Drive each transmission main shaft and drive the conveyor chain to operate; control the bar lifting cylinder to perform small and continuous lifting and lowering and cooperate with the vibration of the vibrating frame to guide the bar to the top of the conveyor chain. After the matching pressure sensor detects that the bar is completely in place, stop the vibration of the vibrating frame and the action of the bar lifting cylinder.

[0030] S6. The rebar translation and conveying mechanism continues to lift and raise the rebar to a suitable height under the action of the lifting mechanism; the walking drive motor is started, driving the walking mechanism to move horizontally along the guide walking frame towards the downstream workstation; when it moves to the preset forward position of the downstream workstation, the walking mechanism stops; the controller starts the matching power components of each chain drive component, driving the drive shaft and the conveyor chain to perform step-by-step operation, while the rebar baffle rotates synchronously with the drive shaft, accurately pushing the rebar to the downstream processing workstation;

[0031] S7. Repeat the cycle until the last steel bar is pushed out, at which point all components reset.

[0032] To ensure the parallel state of the reinforcing bars after entering the conveyor chain and improve the accuracy of the conveying state to the downstream processing station, a reinforcing bar posture correction step is added in step S5: the configured vision sensor collects real-time images of the reinforcing bars in the split state, the controller extracts the edges of the reinforcing bars and fits the length axis of the images, and calculates the angle between the length direction of the reinforcing bars and the conveying direction; when the angle exceeds the preset threshold, the controller controls the conveyor chain on the corresponding side to fine-tune the operating speed, and at the same time controls the split lifting cylinder to complete a small stroke lifting and lowering of the reinforcing bars above it on one side, guiding the reinforcing bars to adjust to a horizontal posture parallel to the conveying direction, until the vision sensor detects that the angle is less than the preset threshold, and then stops the vibration of the vibrating frame and the action of the split lifting cylinder.

[0033] In the split reinforcement state, the conveyor chain is only used to fine-tune the inclination angle of the reinforcement and does not transport the reinforcement downwards; horizontal displacement in the split reinforcement state is achieved by the traveling mechanism.

[0034] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0035] 1. This invention sequentially completes the processes of steel bar dismantling, separating, lifting, and horizontal conveying during production. Seamless integration between each step is achieved through sensor feedback and controller commands: steel bar specifications and flatness data collected by upstream vision sensors can directly serve as the basis for adjusting the docking position of the downstream traveling mechanism, the height of the lifting cylinder group, and the operating speed of the conveyor chain; the vibration frequency and lifting amplitude parameters of the separating stage can be adapted to the power output of the transfer stage based on the weight of the steel bars; and the adjustment parameters of the posture correction stage provide a precise reference for the stepping distance of the feeding stage. Compared to the traditional equipment where each step operates independently and requires manual coordination, the fully integrated design of this invention shortens the overall cycle time for feeding a single steel bar, eliminates production line jams caused by poor step connections, and ensures continuous and stable operation when producing multiple specifications of steel bars on a mixed line.

[0036] 2. This invention collects rebar specification data through a visual sensor. The controller can automatically match the vibration frequency, rebar lifting amplitude, pulse air nozzle jet parameters, transfer height, and feeding step distance corresponding to rebars of different diameters. Compared with the limitation of traditional fixed-parameter equipment that can only adapt to a single specification of rebar, this invention can seamlessly switch between feeding multiple specifications of rebar without manual adjustment, thus broadening the equipment's adaptability and meeting the flexible production needs of modern production lines for multiple varieties and small batches.

[0037] 3. For thin, high-strength, and easily damaged reinforcing bars, the controller automatically lowers the vibration frequency, reduces the lifting amplitude, and slows down the conveyor chain. This coordinated action of low-frequency micro-vibration, flexible lifting, and low-speed connection avoids hard contact friction. For thick, heavy, and rigid reinforcing bars, the vibration and lifting parameters are appropriately increased to quickly break up any adhesion between the bars. Dynamic adaptation of parameters throughout the entire process reduces the surface damage rate of the reinforcing bars, ensuring consistent quality in downstream processing steps.

[0038] 4. The rebar separation process uses visual feedback for targeted calibration, the transfer process uses pressure sensors to accurately determine the rebar's positioning status, and the feeding process uses parameter coordination to avoid interference. Compared to the traditional time threshold control mode, the time of invalid actions is reduced, the feeding cycle of a single rebar is shortened, and the equipment failure rate caused by jamming or misalignment is reduced, thus improving the continuous and stable operation capability of the production line. Attached Figure Description

[0039] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or components are generally identified by similar reference numerals. In the drawings, the elements or components are not necessarily drawn to scale.

[0040] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0041] Figure 2 This is a three-dimensional structural diagram of the feeding and conveying unit of the present invention.

[0042] Figure 3 for Figure 2 A schematic diagram of the main structure.

[0043] Figure 4 for Figure 2 A top-view structural diagram.

[0044] Figure 5 for Figure 2 A side view structural diagram.

[0045] Figure 6 This is a partial structural schematic diagram of the conical lifter and pulse nozzle of the present invention.

[0046] In the diagram, 1. Bulk material unit; 2. Feeding and conveying unit; 3. First frame; 4. Vibrator; 5. Vibrating frame; 6. Rib lifting cylinder; 7. Conical lifting device; 8. Pulse air nozzle; 9. Rotary motor; 10. Clamping device; 11. First baffle plate; 12. Guide walking frame; 13. Lifting cylinder assembly; 14. Walking frame; 15. Walking wheel; 16. Limit wheel seat; 17. Rack; 18. Drive gear; 19. Reducer; 20. Walking drive motor; 21. Lifting storage rack; 22. Transmission main shaft; 23. Driven sprocket; 24. Drive sprocket; 25. Rebar baffle; 26. Rebar; 27. Conveyor chain. Detailed Implementation

[0047] The embodiments of the technical solution of the present invention will now be described in detail with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and are therefore merely examples and should not be used to limit the scope of protection of the present invention. The specific structure of the present invention is as follows: Figures 1-6 As shown in the image.

[0048] Example 1: A rebar vibratory feeding mechanism includes several spaced-apart bulk material units 1. Feeding and conveying units 2 are respectively arranged between adjacent bulk material units 1 and on the outer side of the outermost bulk material unit 1. The bottoms of each bulk material unit 1 and each feeding and conveying unit 2 are fixed to the ground. Each bulk material unit 1 includes a first frame 3, the bottom of which is fixedly installed. Vibratory breakers are installed at the four corners of the top of the first frame 3. A rebar separating mechanism is installed in the central space of the vibratory breaker, and the bottom of the rebar separating mechanism is installed on the top of the first frame 3. Each vibratory breaker includes several vibrators 4 fixedly installed at the four corners of the top of the first frame 3, and a vibratory frame 5 is installed on the top of each vibrator 4.

[0049] This invention enables full automation of the steel bar feeding process. Each unit is fixed to the ground to form a stable support foundation, avoiding overall displacement due to vibration or translation during operation.

[0050] The bulk material unit 1 uses the first frame 3 as its core support. The vibrators 4 at the four corners of its top form the power source for the vibratory breaker. When the vibrators 4 are working, they transmit high-frequency vibrations to the vibratory frame 5 at the top, causing the bundled steel bars placed on the vibratory frame 5 to loosen and separate under the action of vibration. The bar-separating mechanism is installed in the middle space of the vibratory breaker and fixed to the first frame 3 at the bottom. It can intervene in the bar-separating operation simultaneously during the steel bar breaking process. The bar-separating mechanism separates two steel bars that are gathered together by lifting them. The rigid support of the first frame 3 ensures the accuracy of the bar-separating action during bar separation.

[0051] The material conveying unit 2 between adjacent bulk material units 1 and on the outer edge can realize the all-round reception and transfer of steel bars after bulk material is distributed, so as to avoid steel bars falling off.

[0052] In the overall structure, the spatial layout of the vibratory breaker and the reinforcement separation mechanism forms a linkage operation area. The vibration of the vibratory frame 5 provides an auxiliary loosening effect for the reinforcement separation, while the reinforcement separation mechanism lifts, separates, and tidies up the vibrated and broken steel bars. The two work together to complete the pre-processing of steel bar dispersal and reinforcement separation. Then, the loading and conveying unit 2 transports the tidyed steel bars to the downstream work station, realizing the seamless connection of dispersal, reinforcement separation, and transportation.

[0053] Through the rational layout of the bulk material unit 1 and the feeding and conveying unit 2, the entire process of bundled steel bars from bulk material and bar separation to transportation is automated, greatly reducing manual intervention.

[0054] The vibratory breaker, consisting of various vibrators 4 at the corners, can generate uniform vibration to ensure that bundled steel bars are fully broken up and avoid local stacking. The coordination between the bar-separating mechanism and the vibratory breaker enables the material to be broken up and the bars to be separated simultaneously, improving work efficiency.

[0055] In addition, the combination of the vibratory breaker and the rib-separating mechanism allows the rib-separating mechanism to improve the rib-separating effect by using vibration inertia, thereby reducing the power consumption of rib-separating.

[0056] Based on any of the above technical solutions, a further optimization is made as follows: the rib-splitting mechanism includes a rib-splitting lifting cylinder 6 fixedly installed on the top of the first frame 3, the top of the rib-splitting lifting cylinder 6 extending into the corresponding space of the vibrating frame 5, and a rib-splitting device fixedly installed on the top of the telescopic end of the rib-splitting lifting cylinder 6.

[0057] The rebar separator is raised and lowered by the telescopic drive of the rebar separator lifting cylinder 6, achieving precise rebar separation after disintegration and avoiding rebar stacking or tangling. The rebar separator can directly act on the rebar on the vibratory frame 5, resulting in high rebar separation efficiency; the lifting amplitude parameter of the rebar separator lifting cylinder 6 can be flexibly adjusted to adapt to the rebar separation requirements of different specifications.

[0058] It overcomes the limitations of traditional rebar separation mechanisms with fixed spacing. Through the adjustable lifting motion of the rebar separation lifting cylinder 6, it achieves dynamic adaptation of the rebar spacing, which can accommodate rebars of different diameters from Φ12mm to Φ32mm, greatly improving the equipment's versatility. The coordinated operation design of the rebar separation lifting cylinder 6 and the vibratory separator allows the rebar separation action to be carried out by the vibration and loosening of the rebar, greatly reducing the required lifting force, reducing the power consumption of the rebar separation mechanism, and avoiding damage to the rebar surface caused by forced rebar separation.

[0059] In addition, the conical rebar separator can penetrate deep into the rebar stacking area, resulting in a greater rebar separation depth and a better rebar separation effect for deeply stacked rebars. Compared with traditional surface rebar separation mechanisms, the rebar separation qualification rate is improved. The precise extension and retraction control of the rebar lifting cylinder 6 enables intermittent rebar separation, which matches the receiving rhythm of the subsequent feeding and conveying unit 2. This avoids secondary stacking of rebars caused by prolonged residence after rebar separation, ensuring the continuity of the operation process and improving the overall feeding efficiency.

[0060] Based on any of the above technical solutions, a further optimization is made: the reinforcing bar separator includes a conical lifting device 7 fixedly installed on the top of the piston rod of the reinforcing bar lifting cylinder 6. The conical lifting device 7 is used to follow the lifting and lowering of the reinforcing bar lifting cylinder 6 and separate adjacent reinforcing bars by lifting them upwards and flattening them on the top of the vibrating frame 5.

[0061] Based on any of the above technical solutions, a further optimization is made as follows: pre-reinforcement components are installed on the top sides of the first frame 3 on both sides of the conical jack 7. The pre-reinforcement components include pulse nozzles 8 fixedly installed on the top of the first frame 3. The outlet end of the pulse nozzles 8 is oriented and used to blow away adjacent steel bars.

[0062] The tilt angle of each pulse air nozzle 8 can be adjusted as needed along the direction of the steel bar spacing.

[0063] The conical jacking device 7 is fixed to the top of the piston rod of the reinforcing bar lifting cylinder 6. Utilizing the guiding characteristics of the conical structure, it squeezes and separates adjacent reinforcing bars to both sides through the conical surface during the lifting process. Compared with the planar lifting structure, the conical surface can reduce the contact area with the reinforcing bars, reduce friction damage, and improve the separation guiding effect.

[0064] The pulse nozzle 8 of the pre-reinforcement component is installed on the top of the first frame 3 and located on both sides of the conical jack 7. The outlet end faces the area where the steel bars are stacked. During operation, it starts before the conical jack 7 and periodically sprays high-pressure air to initially loosen the bundled steel bars and blow away the adjacent sticky steel bars, laying the foundation for the main reinforcement separation operation of the conical jack 7.

[0065] The tilt angle of the pulse nozzle 8 can be adjusted along the direction of the steel bar spacing. The controller adjusts the tilt angle and jet intensity of different nozzles according to the steel bar specifications and laying status, so that the airflow can be accurately applied to the gaps between the steel bars, avoiding airflow waste or incomplete steel bar separation.

[0066] During operation, the pulse air nozzle 8 first loosens the pre-reinforcement bars, and then the conical jack 7 follows the lifting cylinder 6 to lift and lower the main reinforcement bars. The two work together to achieve the pre-loosening and precise separation process of the reinforcement bars, ensuring that the spacing between adjacent reinforcement bars meets the preset requirements.

[0067] Each of the pulse nozzles 8 is connected to an external air source via a hose. A rotary motor 9 is fixedly installed on a frame on one side of each pulse nozzle 8. The motor shaft end of the rotary motor 9 is fixed to the outer side wall of the pulse nozzle 8 via a clamp 10. When the rotary motor 9 rotates, it drives the pulse nozzle 8 to adjust the tilt angle along the front-back direction.

[0068] The pulse air nozzle 8 pre-divides the reinforcing bars and has an adjustable tilt angle, which can loosen the bonded reinforcing bars in advance, adapt to different reinforcing bar division requirements, and reduce the difficulty of main reinforcing bar division; the conical jack 7 uses the conical surface guide to achieve precise reinforcing bar division and ensure uniform spacing between adjacent reinforcing bars; in addition, the conical structure reduces the contact area with the reinforcing bars and reduces surface damage.

[0069] By adjusting the tilt angle of the designed pulse nozzle 8, the airflow can be precisely applied to the gaps between steel bars at different locations, avoiding the blind spots present in traditional fixed nozzles for steel bar division. This results in better steel bar division for irregularly stacked steel bars. The combination of airflow pre-division and the main steel bar division of the conical jack 7 improves the steel bar division efficiency. The working rhythm can be dynamically adjusted according to the thickness of the steel bar stack. When the stack is thicker, the jet intensity and frequency of the pulse nozzle 8 are increased, and when the stack is thinner, the main steel bar division stroke is reduced, achieving adaptive adjustment of the steel bar division process and further enhancing the intelligence level and operational flexibility of the equipment.

[0070] Based on any of the above technical solutions, a further optimization is made as follows: a plurality of first baffle plates 11 are welded at intervals along the length of the reinforcing bars on the top front side of the vibrating frame 5. The first baffle plates 11 are used to prevent the reinforcing bars from slipping backward when following the vibration.

[0071] The first retaining plate 11 is welded at intervals along the length of the reinforcing bar to the top of the front side of the vibratory machine frame 5, forming a longitudinal blocking barrier. Its welding and fixing method ensures the rigidity of the connection with the vibratory machine frame 5, and avoids loosening or deformation during high-frequency vibration.

[0072] During operation, the vibrating frame 5 generates high-frequency vibration under the drive of the vibrator 4, causing the steel bars on it to vibrate slightly in the up-down and back-and-forth directions. During the vibration, the steel bars tend to slide backward. At this time, the height of the first baffle plate 11 is higher than the top surface of the vibrating frame 5 but lower than the placement height of the steel bars. This can physically block the backward displacement of the steel bars without affecting the lateral division and longitudinal movement of the steel bars.

[0073] The spaced arrangement design ensures effective blocking of rebars of varying lengths, preventing situations where excessively long rebars leave their ends unprotected. Furthermore, the spacing between the retaining plates can be preset based on common rebar lengths, ensuring that the distance between adjacent plates is less than the length of the smallest rebar, achieving full-length blocking protection.

[0074] Based on any of the above technical solutions, a further optimization is made as follows: the feeding and conveying unit 2 includes a guide walking frame 12 fixed on the ground, a walking mechanism for translating along the direction of the steel bar spacing is provided above the guide walking frame 12, and a steel bar translating and conveying mechanism is installed above the walking mechanism. The steel bar translating and conveying mechanism is used to support and convey each steel bar to be conveyed to the downstream work station; the steel bar translating and conveying mechanism is driven by a matching power component.

[0075] The material conveying unit 2 uses the guide walking frame 12 as its translational guide foundation, with its bottom fixed to the ground, providing stable support for the entire conveying unit. The walking mechanism is located above the guide walking frame 12 and can perform linear translation along the direction of the rebar spacing. Its translational trajectory is precisely constrained by the guide structure of the guide walking frame 12. The rebar translational conveying mechanism is installed above the walking mechanism and serves as the core component for rebar support and conveying. It is driven by a matching power unit to achieve longitudinal conveying of the rebar (along the conveying direction). During operation, the controller sends a translation command to the walking mechanism based on the rebar laying range of the bulk material unit 1. The walking mechanism moves along the guide walking frame 12 to the receiving position corresponding to the bulk material unit 1. Then, the rebar translational conveying mechanism starts to support the rebar transferred from the bulk material unit 1. After receiving, the walking mechanism starts again, driving the rebar translational conveying mechanism to translate along the guide walking frame 12 towards the downstream workstation. After reaching the designated position, the rebar translational conveying mechanism conveys the rebar to the downstream workstation, completing the transfer process of receiving, translation, and conveying. The guiding structure of the guiding walking frame 12 ensures the straightness of the walking mechanism during translation, and avoids the steel bars falling off or misalignment due to translation deviation.

[0076] The layered design of the traveling mechanism and the steel bar translation and conveying mechanism allows the translation and conveying actions to be independent yet coordinated. The translation speed and conveying speed can be flexibly adjusted according to the operation requirements, so as to achieve precise matching between the transfer rhythm, the bulk material rhythm and the downstream processing rhythm, and improve the overall efficiency of the production line.

[0077] Based on any of the above technical solutions, a further optimization is made as follows: the rebar translation and conveying mechanism is connected to the traveling mechanism through a lifting mechanism; the lifting mechanism includes two lifting cylinder groups 13 spaced apart on both sides of the top of the traveling mechanism, the two lifting cylinder groups 13 move up and down synchronously during operation and have a locking function, the bottom of each lifting cylinder group 13 is fixed to the top of the traveling mechanism and the top of each lifting cylinder group 13 is fixed to the bottom of the rebar translation and conveying mechanism, and the lifting mechanism drives the rebar translation and conveying mechanism and the rebars on it to move up and down through its own lifting and down and match the height of different downstream work positions.

[0078] The lifting mechanism, serving as the intermediate component connecting the rebar transfer and conveying mechanism and the traveling mechanism, is primarily composed of lifting cylinder assemblies 13 spaced apart on both sides. Synchronous lifting adjusts the height of the rebar transfer and conveying mechanism. The bottoms of the two lifting cylinder assemblies 13 are fixed to the top of the traveling mechanism, and the tops are fixed to the bottom of the rebar transfer and conveying mechanism, forming a symmetrical support structure to ensure the horizontality of the rebar transfer and conveying mechanism during lifting. During operation, the controller sends synchronous lifting commands to the two lifting cylinder assemblies 13 based on the height (bearing height) of the vibrating frame 5 of the bulk material unit 1 and the feeding height of the downstream station. The hydraulic or pneumatic system drives the lifting cylinder assemblies 13 to extend and retract, raising and lowering the rebar transfer and conveying mechanism to the target height. The lifting cylinder assemblies 13 have a locking function, automatically locking upon reaching the target height to prevent height deviation due to pressure changes during operation. Synchronous lifting control adjusts the extension and retraction speed and stroke of the two lifting cylinder assemblies 13 through the controller, ensuring that the lifting deviation is less than 1mm, guaranteeing that the rebar transfer and conveying mechanism does not tilt during lifting and preventing the rebar from falling off.

[0079] Throughout the adjustment process, the height of the steel bar translation and conveying mechanism is adjusted synchronously by lifting cylinder group 13 to adapt to the feeding height of bulk material unit 1 and downstream workstations. It can adapt to the needs of different specifications of bulk material unit 1 (different heights of vibrating frame 5) and different downstream processing workstations (different feeding heights), greatly improving equipment compatibility and adapting to a wider range of heights, covering the height requirements of most steel bar processing production lines.

[0080] In addition, the synchronous lifting control and symmetrical support design of the two lifting cylinder groups 13 ensure that the lifting level deviation of the rebar translation conveying mechanism is controlled within ±1mm, avoiding rebar displacement or falling due to mechanism tilting and improving transfer stability. The modular connection design of the lifting mechanism, the traveling mechanism, and the rebar translation conveying mechanism makes the entire equipment easy to install, maintain, and replace. At the same time, the lifting parameters can be adjusted individually according to actual needs, improving the equipment's operational flexibility, reducing maintenance costs, and improving maintenance efficiency compared to traditional integrated conveying mechanisms.

[0081] Based on any of the above technical solutions, a further optimization is made as follows: the walking mechanism includes a walking frame 14 disposed on the top of the guide walking frame 12, and walking wheels 15 are movably installed at the four bottom corners of the walking frame 14. The bottom of each walking wheel 15 movably abuts against the guide plane at the top. Limiting wheel seats 16 that abut against the corresponding sides of the guide walking frame 12 are fixed at the four corners of the walking frame 14. The axles of each walking wheel 15 are movably inserted into the corresponding shaft holes of the limiting wheel seats 16. A translation driver is installed in the middle of the walking frame 14.

[0082] The traveling mechanism uses the traveling frame 14 as its core support. The traveling wheels 15 at the four corners of the bottom form a rolling engagement with the guide plane at the top of the guide traveling frame 12, reducing friction during translation and improving smoothness. The limiting wheel seats 16 at the four corners abut against the corresponding sides of the guide traveling frame 12, forming a lateral limiting constraint to prevent the traveling frame 14 from shifting laterally during translation and to ensure the straightness of the translation trajectory.

[0083] The axle of the traveling wheel 15 is movably inserted into the shaft hole of the limiting wheel seat 16, allowing the traveling wheel 15 to rotate flexibly. At the same time, the limiting wheel seat 16 provides stable support for the axle, preventing axle deformation. The translation drive is installed in the middle of the traveling frame 14, providing translational force for the traveling mechanism. During operation, the translation drive is activated, driving the traveling wheel 15 to roll along the guide plane, thereby driving the entire traveling frame 14 to translate along the guide traveling frame 12. The abutting engagement between the limiting wheel seat 16 and the side of the guide traveling frame 12 can correct the lateral offset of the traveling frame 14 in real time, ensuring that the traveling mechanism always translates along the preset trajectory, guaranteeing accurate docking with the bulk material unit 1 and downstream workstations.

[0084] Based on any of the above technical solutions, a further optimization is made as follows: the translation driver includes a rack 17 fixed to the top of the middle section of the guide walking frame 12 and arranged along its length direction, a horizontally arranged drive gear 18 meshing on one side of the rack 17, the drive gear 18 fixing the output end of the walking drive motor 20 with a reducer 19 above it, and the walking drive motor 20 being fixed as a whole on the walking frame 14.

[0085] The translational drive uses a rack and pinion 17-gear meshing transmission method to achieve precise translational drive of the traveling mechanism. The rack 17 is fixed to the top of the middle section of the guide traveling frame 12 and extends along its length, providing a fixed transmission track for translation; the drive gear 18 meshes with the rack 17 and is fixed to the output end of the traveling drive motor 20 with reducer 19.

[0086] During operation, the controller sends speed and direction commands to the drive motor 20. The power output by the motor is adjusted in speed and torque by the reducer 19, which then drives the drive gear 18 to rotate. The drive gear 18 meshes with the rack 17, converting the rotational power into linear translational force for the walking frame 14, driving the walking frame 14 to translate along the guide frame 12. The reduction ratio of the reducer 19 can be preset according to the translational speed requirements, achieving stepless adjustment of the translational speed. At the same time, the meshing transmission between the gear and rack 17 has high-precision positioning characteristics, and precise displacement control of the walking mechanism can be achieved by controlling the rotation angle of the motor.

[0087] The design of the rack 17 being fixed to the guide frame 12 and the drive gear 18 moving with the walking frame 14 makes the transmission structure simple and compact, easy to install and maintain. At the same time, the meshing clearance between the gear and the rack 17 can be finely adjusted by the adjustment mechanism to reduce transmission error and further improve translation accuracy. Compared with traditional complex transmission mechanisms, the maintenance cost is reduced.

[0088] Based on any of the above technical solutions, a further optimization is made as follows: the rebar translation and conveying mechanism includes a lifting storage rack 21 fixed on the top of the lifting mechanism and arranged along the conveying direction of the rebar. Chain drive assemblies are symmetrically installed on the two side walls of the lifting storage rack 21. The rear ends of the two chain drive assemblies are connected through a drive shaft 22, which is driven by an externally matched power component. The drive shafts 22 on each of the rebar translation and conveying mechanisms operate synchronously and realize step-by-step feeding of the rebar to be conveyed.

[0089] The chain drive assembly includes two driven sprockets 23 respectively inserted into the front side wall of the lifting storage rack 21. Drive sprockets 24 are respectively spaced apart on the rear side of each driven sprocket 23. Each drive sprocket 24 is coaxially fixed to the end of the transmission main shaft 22. The driven sprockets 23 and the drive sprockets 24 on the same side are connected by a transmission chain 27. The top of each transmission chain 27 is used to support the reinforcing bars.

[0090] Based on any of the above technical solutions, a further optimization is made as follows: a steel bar baffle 25 is fixedly connected to the end of each of the transmission main shafts 22. The steel bar baffle 25 is vertically set in the normal state and is used to block and limit the steel bars upstream of it. When the steel bar baffle 25 rotates with the transmission main shaft 22, its free end can push the current steel bar downstream. Each of the steel bar baffles 25 is in a synchronous operation state when working and does not interfere with the movement of other parts when rotating in the circumferential direction.

[0091] The rebar conveying mechanism uses a lifting storage rack 21 as its load-bearing frame and symmetrical chain drive assemblies on both sides as its core conveying structure. Synchronous drive is achieved through an external drive shaft 22. The chain drive assembly consists of a driven sprocket 23, a drive sprocket 24, and a conveyor chain. The drive sprocket 24 is coaxially fixed to the end of the drive shaft 22, and the driven sprocket 23 is inserted into the front side wall of the lifting storage rack 21. The conveyor chain connects the two to form a closed transmission chain, with the top of the conveyor chain serving as a rebar support surface.

[0092] An external power unit drives the transmission main shaft 22 to rotate, which in turn drives the two drive sprockets 24 to rotate synchronously. This, in turn, drives the conveyor chain to circulate along the driven sprocket 23 and the drive sprocket 24, thus conveying the reinforcing bars. The reinforcing bar baffle 25 at the end of the transmission main shaft 22 is normally vertically positioned, blocking and limiting the upstream reinforcing bars to prevent premature slippage. When feeding is required, the rotation of the transmission main shaft 22 drives the reinforcing bar baffle 25 to rotate synchronously. The free end of the baffle pushes the reinforcing bars to move downstream, achieving step-by-step feeding. After rotating one revolution, the reinforcing bar baffle 25 returns to the vertical position and blocks the subsequent conveyed reinforcing bars after splitting. The transmission main shafts 22 of each reinforcing bar translation conveying mechanism maintain synchronous operation, ensuring coordinated feeding by multiple conveying mechanisms and preventing deviation caused by uneven force on the reinforcing bars. Simultaneously, the rotation trajectory of the reinforcing bar baffle 25 is precisely designed to ensure no interference with other parts during circumferential rotation.

[0093] In this technical solution, the transmission spindle 22 drives the chain transmission components on both sides to operate synchronously, preventing the rebar from shifting; the rebar baffle 25 realizes the dual functions of blocking and limiting and feeding; this step-feeding design breaks through the limitations of continuous feeding in traditional conveying mechanisms, and realizes precise step-by-step pushing of rebar through the synchronous rotation of the rebar baffle 25. The feeding step distance can be precisely controlled, adapting to the intermittent processing needs of downstream stations, avoiding rebar accumulation or waiting, and improving the coordination of the production line.

[0094] The design of the symmetrical chain drive components on both sides and the synchronous drive of the main drive shaft 22 ensures better synchronization of the conveyor chain operation, ensuring that the steel bars remain horizontal during the conveying process and avoiding lateral deviation. The conveying accuracy is significantly better than that of traditional single chain drives. The synchronous operation design of the main drive shaft 22 of the multi-steel bar translation conveying mechanism allows multiple sets of mechanisms to work together to receive and convey long steel bars, avoiding bending deformation of long steel bars caused by single-point support. It can be adapted to the conveying of steel bars of larger lengths, expanding the adaptability of the equipment, while ensuring the stability of the posture of long steel bars during the conveying process, providing accurate steel bar posture for subsequent processing.

[0095] The present invention also provides a rebar intelligent vibration feeding system, including the rebar vibration feeding mechanism as described above, and a downstream processing station is provided downstream of the rebar vibration feeding mechanism.

[0096] When the feeding system is working, the vibrating feeding mechanism for reinforcing bars completes the unpacking, separation, and transfer of bundled reinforcing bars according to a preset process, accurately delivering the sized reinforcing bars to the feeding end of the downstream reinforcing bar processing station. The feeding equipment and the processing station coordinate through signal interaction: the status sensors of the processing station provide real-time feedback to the system controller regarding station availability; when the station is idle, the controller instructs the feeding equipment to start the feeding process; when the station is processing, the feeding equipment pauses feeding and temporarily stores the reinforcing bars on the conveyor mechanism. Simultaneously, the lifting mechanism of the feeding equipment can adjust the conveying height in real-time according to the feeding height of the processing station, ensuring the reinforcing bars smoothly enter the processing station; the traveling mechanism can precisely adjust its translation position according to the feeding position of the processing station, achieving precise docking. The system controller coordinates the working rhythm of each mechanism of the feeding equipment and the processing station, forming a closed-loop control to ensure seamless connection between the feeding and processing processes, avoiding feeding delays or accumulation problems.

[0097] Example 2: Compared with Example 1, this example also includes the following technical features:

[0098] The present invention also provides a method for intelligent vibration feeding of reinforcing bars using the above-mentioned equipment, comprising the following steps:

[0099] S1. Bundles of steel bars are hoisted to the top of bulk material unit 1, and unbundled after calibration and positioning.

[0100] S2. Start the bulk material unit 1 to vibrate and disperse the material and divide it into intermittent sections. Adjust the frequency of the vibrator 4 according to the preset steel bar specifications. The lifting cylinder 6 drives the conical lifting device 7 to rise and fall intermittently, and cooperates with the pulse air nozzle 8 to periodically spray air to complete the dispersing, initial division and flattening of the steel bars.

[0101] S3. The controller collects flat images through the matching visual sensor, analyzes whether the spacing of the steel bars in the image meets the standard and whether there is any stacking or entanglement. If it does not meet the standard, the controller adjusts the tilt angle of the corresponding pulse nozzle 8, the jet intensity and the lifting cylinder amplitude, and then performs a second calibration until it meets the standard.

[0102] The advantages of the above steps are as follows: Traditional reinforcement alignment calibration often adopts a uniform adjustment mode across the entire area. This means that when reinforcement is found to be substandard, the parameters of the vibrator 4 and reinforcement components in the entire bulk material area are adjusted. This not only easily leads to the re-accumulation of reinforcement in the qualified areas but also results in wasted power. In contrast, this step uses a visual sensor to precisely locate the coordinates of the substandard area. The controller then selectively adjusts the tilt angle, jet intensity, and amplitude of the reinforcement lifting cylinder 6 corresponding to that area, achieving targeted calibration. This precise control method avoids unnecessary intervention in qualified areas, improving the success rate of reinforcement alignment calibration. Furthermore, compared to uniform adjustment, the energy consumption of the pulse nozzle 8 and the lifting cylinder is reduced, significantly improving the energy efficiency of the reinforcement alignment process.

[0103] In this step, the flat image data collected by the vision sensor can provide real-time feedback on the differences in the reinforcement status of steel bars of different specifications. The controller analyzes the deviations of the steel bar spacing, stacking shape, and preset thresholds in the image, and automatically matches the optimal adjustment scheme for the air nozzle tilt angle, air jet intensity, and lifting cylinder amplitude to form a dynamic adaptation. Precise reinforcement of steel bars of different diameters and lengths can be achieved without manual intervention, greatly improving the flexible production capacity of the production line.

[0104] In addition, this step uses visual precision to detect the degree of stacking and adhesion of non-conforming areas, and the controller fine-tunes the parameters as needed: for slightly adhered areas, simply adjusting the nozzle angle to enhance local air jetting is enough to separate them; for areas with thicker stacking, the air jetting of the nozzle and the lifting cylinder are coordinated to work together in a small lifting motion to avoid damage to the steel bars caused by excessive parameters.

[0105] Furthermore, traditional rebar separation processes lack precise detection of the rebar's laid-out state. Even after separation, hidden problems such as uneven rebar spacing and minor local entanglement can easily exist. These issues directly lead to posture deviations when the rebar is transferred to the conveyor belt, increasing the difficulty and cost of subsequent posture correction. This step uses visual image analysis to rigorously verify the rebar spacing and stacking / entanglement state, ensuring that the rebar entering the subsequent transfer stage fully meets the requirements for laid-out separation. This keeps the initial posture deviation of the rebar when transferred to the conveyor belt within ±2mm. This high-precision pre-separation guarantee significantly reduces the adjustment range and time of posture correction in the subsequent S5 step, shortening the overall feeding cycle time and providing stable feeding assurance for downstream high-precision processing stations.

[0106] S4. The controller controls the movement of the walking mechanism based on the rebar laying range fed back by the visual sensor. When the mechanism moves to the docking position, the positioning switch is triggered to achieve precise positioning. The lifting cylinder group 13 drives the conveying mechanism to rise to the same height as the vibrating frame 5 and then locks it.

[0107] This step is not an isolated docking action, but rather it is linked with upstream steps S2 and S3 through visual sensor data: when a large area of ​​a certain specification of rebar is detected to be laid out, the controller can optimize the upstream rebar distribution parameters (such as fine-tuning the vibration frequency and increasing the jet intensity of the pulse air nozzle 8) to make the rebar laying more compact and uniform, thereby reducing the docking stroke of the traveling mechanism and shortening the docking time; at the same time, the lifting speed of the lifting cylinder group 13 is adjusted according to the laying area, using a slow lifting and slow lowering with stable locking mode for large-specification, heavy-weight rebar, and a fast lifting and fast lowering with precise locking mode for small-specification, light-weight rebar, to achieve optimal adaptation of the docking rhythm of different rebar specifications. This improves the overall cycle efficiency of multi-specification rebar feeding, avoids process interruptions caused by adjustments in a single step, and ensures the continuous and stable operation of the production line.

[0108] S5. Drive each transmission main shaft 22 and drive the conveyor chain to operate; control the bar lifting cylinder 6 to perform small and continuous lifting and lowering, and cooperate with the vibration of the vibrating frame 5 to guide the bar to the top of the conveyor chain. After the matching pressure sensor detects that the bar is completely in place, stop the vibration of the vibrating frame 5 and the action of the bar lifting cylinder 6.

[0109] In traditional processes, when processing steel bars with large diameter differences (such as Φ12mm thin steel bars and Φ32mm thick steel bars) or large length spans (such as 3m short steel bars and 12m long steel bars), fixed parameters can easily cause thin steel bars to bounce and shift due to excessive vibration intensity, thick steel bars to be unable to detach from the vibrating frame 5 due to insufficient vibration intensity, and long steel bars to droop and get stuck at the end due to insufficient lifting stroke.

[0110] In this step, the controller automatically matches the vibration frequency of the vibratory frame 5 with the small lifting parameters of the lifting cylinder 6 based on the rebar specification data (diameter, length) collected by the upstream visual sensor: for thin and short rebars, the vibration frequency is reduced to 50-80Hz, and the lifting cylinder's lifting amplitude is reduced to 5-10mm to prevent the rebars from bouncing or shifting; for thick and long rebars, the vibration frequency is increased to 100-150Hz, and the lifting cylinder's lifting amplitude is increased to 10-15mm, using stronger vibration and lifting forces to assist the rebars in detaching from the vibratory frame 5 and landing smoothly. This adaptive parameter adjustment design improves the transfer success rate of rebars of different specifications, completely solving the technical problem of poor adaptability of traditional fixed parameters.

[0111] In addition, traditional steel bar transfer methods often use strong vibration and forced pushing, which can easily cause severe friction or collision between the steel bars and the vibrating frame and conveyor chain. This is especially true for high-strength threaded steel bars and other steel bars with high surface precision requirements, resulting in a high damage rate.

[0112] The core advantage of this step lies in the controller's dynamic coordination of the vibration frequency, lifting amplitude, and conveyor chain speed based on the rebar specifications. For thin rebars that are easily damaged, the vibratory frame 5 is controlled to vibrate at a low frequency, while the rebar lifting cylinder 6 moves up and down at a small amplitude and uniform speed. At the same time, the conveyor chain speed is reduced, allowing the rebars to be transferred smoothly under the effects of weak vibration buffering, flexible lifting guidance, and low-speed conveying, reducing hard contact friction. For thick rebars with high rigidity, the vibration frequency and lifting amplitude are appropriately increased, and the conveyor chain is accelerated synchronously. The vibration force and lifting force are used to quickly break the adhesion between the rebars and the vibratory frame 5. At the same time, the synchronous operation of the conveyor chain offsets the impact force of the rebar falling, reducing the surface damage rate of the rebars and ensuring the relative consistency of the quality of subsequent rebar processing.

[0113] Secondly, traditional steel bar transfer methods often use time thresholds as the basis for stopping vibration and lifting, which can easily lead to two problems: first, stopping the operation before the steel bar is fully in place can cause subsequent transfers to stall; second, vibrating and lifting can continue even after the steel bar is in place, resulting in energy waste and component wear.

[0114] In this step, the accompanying pressure sensor collects pressure data from the conveyor chain in real time. The controller presets different pressure thresholds based on the rebar specifications: thinner rebars are lighter and have a lower preset pressure threshold; thicker rebars are heavier and have a higher preset pressure threshold. When the pressure sensor detects that the pressure value has reached the preset threshold and stabilized for 3-5 seconds, it determines that the rebar has been completely and smoothly positioned, and immediately stops the vibration of the vibrating frame 5 and the operation of the rebar lifting cylinder 6. This closed-loop control based on pressure feedback, compared to the traditional time threshold determination method, can reduce invalid vibration and lifting time, reduce equipment energy consumption, and avoid subsequent material jamming failures caused by incomplete rebar positioning, significantly improving the stability and economy of the transfer process.

[0115] S6. The rebar translation and conveying mechanism continues to lift and raise the rebar to a suitable height under the action of the lifting mechanism; the walking drive motor 20 is started, driving the walking mechanism to move horizontally along the guide walking frame 12 towards the downstream workstation; when it moves to the preset forward position of the downstream workstation, the walking mechanism stops; the controller starts the matching power components of each chain drive component, driving the transmission main shaft 22 and the conveyor chain to perform step-by-step operation, while the rebar baffle 25 rotates synchronously with the transmission main shaft 22, accurately pushing the rebar to the downstream processing workstation.

[0116] In this step, the controller can automatically match core parameters based on the rebar specification data collected by the upstream vision sensor: First, the lifting height is adaptive. For large-diameter rebars, the lifting cylinder group 13 is controlled to lift the conveying mechanism to the high limit to avoid the rebars scraping against the feed port of the workstation; for small-diameter rebars, it is adjusted to the low limit to reduce lifting energy consumption and time; Second, the translation speed is graded and controlled. Heavy-duty rebars adopt a low-speed uniform translation mode to reduce the load impact on the walking mechanism, while light rebars adopt a high-speed and efficient translation mode to improve the transfer cycle; Third, the feeding step distance is precisely matched to ensure that the rebar baffle 25 can be accurately pushed every time it is moved.

[0117] S7. Repeat the cycle until the last steel bar is pushed out, at which point all components reset.

[0118] This method is based on the aforementioned rebar vibration feeding mechanism. Through the design of pretreatment, bulk material separation, detection and calibration, docking and acceptance, posture correction, material transfer and transportation, and cyclic reset, it realizes intelligent rebar vibration feeding.

[0119] In step S2, the vibrator 4, the bar-separating lifting cylinder 6, and the pulse air nozzle 8 work together to break up, initially separate, and lay the bundled steel bars. The vibration frequency, lifting, and air jet parameters are preset according to the steel bar specifications. In step S3, images are acquired by a vision sensor and analyzed by the controller. Areas with substandard bar separation are then subjected to targeted secondary calibration to ensure bar separation accuracy. In step S4, based on the laying range fed back by the vision sensor, the walking mechanism is controlled to precisely move and connect. The lifting cylinder group 13 adjusts the height of the conveying mechanism and locks it to ensure stable connection. In step S5, the conveyor chain is driven to operate, coordinating with the bar-separating lifting cylinder 6 and the vibrating frame 5 to guide the steel bar connection. The relevant actions stop after the pressure sensor detects that the steel bars are fully in place. Simultaneously, an additional posture correction mechanism is implemented. The process involves using a vision sensor to acquire images. The controller calculates the angle between the rebar and the conveying direction through edge extraction and axis fitting. When the angle exceeds a threshold, the speed of the corresponding side conveyor chain is fine-tuned, and the single-side small-stroke lifting cylinder 6 is controlled to guide the rebar to a parallel posture. At this time, the conveyor chain is only responsible for posture fine-tuning and does not convey downwards; horizontal movement is achieved by the walking mechanism. In step S6, the conveying mechanism lifts the rebar and moves it to the front position of the downstream station. It then feeds the rebar in a step-by-step manner through chain drive and rebar baffle 25. In step S7, the process repeats until all rebars are fed, and all components are reset to await the next round of operation. It can be seen that the entire process is controlled by the controller to control the actions of each mechanism, combined with sensor feedback to achieve closed-loop control, ensuring precise coordination of each step.

[0120] Throughout the method, visual inspection and secondary calibration ensure the accuracy of rebar separation, and an additional posture correction step ensures that the rebar is parallel to the conveying direction, improving feeding accuracy. The added visually guided rebar posture correction step accurately calculates the rebar tilt angle through edge extraction and axis fitting. Combined with the coordinated correction of conveyor chain fine-tuning and the unilateral lifting of the rebar lifting cylinder 6, the parallelism between the rebar and the conveying direction is well matched, and the feeding posture accuracy is greatly improved. This provides precise rebar posture for downstream processing, reducing downstream processing errors.

[0121] In addition, the transmission chain and the walking mechanism are designed with fine-tuning posture in the split state, and the walking mechanism is horizontally shifted to avoid interference between the two movements. At the same time, unnecessary conveying movements of the transmission chain are reduced, thus reducing energy consumption and component wear.

[0122] To ensure the parallel state of the reinforcing bars after entering the conveyor chain and improve the accuracy of the conveying state to the downstream processing station, a reinforcing bar posture correction step is added in step S5: the configured vision sensor collects real-time images of the reinforcing bars in the split state, the controller extracts the edges of the reinforcing bars and fits the length axis of the images, and calculates the angle between the length direction of the reinforcing bars and the conveying direction; when the angle exceeds the preset threshold, the controller controls the conveyor chain on the corresponding side to fine-tune the operating speed, and at the same time controls the split lifting cylinder 6 to complete a small-stroke lifting and lowering of the reinforcing bars above it on one side, guiding the reinforcing bars to adjust to a horizontal posture parallel to the conveying direction, until the vision sensor detects that the angle is less than the preset threshold, and then stops the vibration of the vibrating frame 5 and the action of the split lifting cylinder 6.

[0123] In the split reinforcement state, the conveyor chain is only used to fine-tune the inclination angle of the reinforcement and does not transport the reinforcement downwards; horizontal displacement in the split reinforcement state is achieved by the traveling mechanism.

[0124] In the above solution, pre-adjusting the reinforcing bars to a parallel state allows them to enter different processing stations (such as bending, cutting, and welding) in a uniform posture, eliminating the need to modify the feeding mechanisms of each processing equipment to accommodate different postures. Compared to the passive mode of traditional processing equipment adapting to the posture of reinforcing bars, this active posture regularization allows the production line to easily accommodate processing equipment of different specifications, especially adapting to intelligent production lines integrating multiple processes, thus reducing equipment modification costs.

[0125] If the reinforcing bars enter the downstream processing equipment without parallel alignment, the feed inlet guide structure and clamping mechanism will experience localized stress concentration due to uneven force distribution, which can easily lead to component deformation and accelerated wear over time. Pre-correction of the parallel alignment ensures uniform force distribution during reinforcing bar feeding, avoiding localized overload and extending the service life of core components such as the feed guide and clamping claws. It also reduces processing accuracy drift caused by component wear, decreases manual intervention, and reduces equipment maintenance frequency and downtime.

[0126] Furthermore, the parallel and regular posture of the rebars provides a stable foundation for downstream intelligent processes such as robot grasping and visual positioning. Robots can plan their grasping paths according to fixed coordinates and posture parameters, eliminating the need for additional posture recognition and adjustment modules and reducing the complexity of the control system. The visual positioning system can quickly and accurately capture the ends of the rebars or key processing points, avoiding positioning errors caused by posture deviations. This is particularly suitable for high-precision rebar assembly and customized processing scenarios, improving the success rate of intelligent processing.

[0127] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention. For those skilled in the art, any alternative improvements or transformations made to the implementation of the present invention fall within the protection scope of the present invention.

[0128] Any aspects of this invention not described in detail are well-known to those skilled in the art.

Claims

1. A rebar vibratory feeding mechanism, characterized in that: The system comprises several spaced-apart bulk material units. A feeding and conveying unit is provided between adjacent bulk material units and on the outer side of the outermost bulk material unit. The bottoms of each bulk material unit and each feeding and conveying unit are fixed to the ground. Each bulk material unit includes a first frame, the bottom of which is fixedly mounted. Vibratory breakers are installed at the four corners of the top of the first frame. A rib-splitting mechanism is installed in the central space of each vibratory breaker, with its bottom mounted on the top of the first frame. Each vibratory breaker includes several vibrators fixedly mounted at the four corners of the top of the first frame, and a vibratory frame is mounted on top of each vibrator.

2. The rebar vibratory feeding mechanism according to claim 1, characterized in that: The rib-splitting mechanism includes a rib-splitting lifting cylinder fixedly installed on the top of the first frame. The top of the rib-splitting lifting cylinder extends into the corresponding space of the vibrating frame, and a rib-splitting device is fixedly installed on the top of the telescopic end of the rib-splitting lifting cylinder.

3. The rebar vibratory feeding mechanism according to claim 2, characterized in that: The reinforcement separator includes a conical jacking device fixedly installed on the top of the piston rod of the reinforcement lifting cylinder. The conical jacking device is used to follow the lifting and lowering of the reinforcement lifting cylinder and separate adjacent reinforcement bars by lifting them upwards and flattening them on the top of the vibratory frame.

4. The rebar vibratory feeding mechanism according to claim 3, characterized in that: Several first retaining plates are welded at intervals along the length of the reinforcing bars on the top front side of the vibrating machine frame. The first retaining plates are used to prevent the reinforcing bars from slipping backward when they follow the vibration.

5. The rebar vibratory feeding mechanism according to claim 4, characterized in that: The material feeding and conveying unit includes a guide walking frame fixed on the ground. Above the guide walking frame is a walking mechanism for translating along the direction of the steel bar spacing. Above the walking mechanism is a steel bar translating and conveying mechanism. The steel bar translating and conveying mechanism is used to support and convey the steel bars to be conveyed to the downstream workstation. The steel bar translating and conveying mechanism is driven by a matching power component.

6. The rebar vibratory feeding mechanism according to claim 5, characterized in that: The rebar translation and conveying mechanism is connected to the traveling mechanism via a lifting mechanism. The lifting mechanism includes two lifting cylinder groups spaced apart on both sides of the top of the traveling mechanism. The two lifting cylinder groups move up and down synchronously during operation and have a locking function. The bottom of each lifting cylinder group is fixed to the top of the traveling mechanism, and the top of each lifting cylinder group is fixed to the bottom of the rebar translation and conveying mechanism. The lifting mechanism drives the rebar translation and conveying mechanism and the rebars on it to move up and down through its own lifting and down, and matches the height of different downstream workstations.

7. The rebar vibratory feeding mechanism according to claim 6, characterized in that: The walking mechanism includes a walking frame disposed on the top of the guide walking frame. Walking wheels are movably installed at the four corners of the bottom of the walking frame. The bottom of each walking wheel movably abuts against the guide plane at the top. Limiting wheel seats that abut against the corresponding sides of the guide walking frame are fixed at the four corners of the walking frame. The axle of each walking wheel is movably inserted into the corresponding shaft hole of the limiting wheel seat. A translation driver is installed in the middle of the walking frame.

8. The rebar vibratory feeding mechanism according to claim 7, characterized in that: The translational drive includes a rack fixed to the top of the middle section of the guide frame and arranged along its length. A horizontally arranged drive gear meshes on one side of the rack. The drive gear is fixed to the output end of a travel drive motor with a reducer above it. The travel drive motor is fixed as a whole on the travel frame.

9. The steel bar vibrating feeding mechanism according to claim 8, characterized in that: The steel bar translation and conveying mechanism includes a lifting storage rack fixed on the top of the lifting mechanism and arranged along the conveying direction of the steel bar. Chain drive assemblies are symmetrically installed on the two side walls of the lifting storage rack. The rear ends of the two chain drive assemblies are connected by a drive shaft, which is driven by an external power component. The drive shafts on each of the steel bar translation and conveying mechanisms operate synchronously and realize step-by-step feeding of the steel bars to be conveyed.

10. A rebar intelligent vibration feeding system, characterized in that: The invention includes a steel bar vibrating feeding mechanism as described in any one of claims 1-9, wherein a downstream processing station is provided downstream of the steel bar vibrating feeding mechanism.

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