Manufacturing method of precast beam top plate reinforcement cage

Abstract

The invention provides a manufacturing method of a precast beam top plate reinforcement cage, and relates to the technical field of precast beam construction.The manufacturing method of the precast beam top plate reinforcement cage comprises the steps that after top bar raw materials and bottom bar raw materials are straightened, sheared and bent, single stirrups are formed through welding; the single stirrups are transferred to the stirrup temporary storage mechanism through the robot to be temporarily stored; the multiple sets of cached single stirrups are grabbed and transferred to a stirrup single piece positioning and conveying mechanism; the multiple single-piece stirrups are tightly arranged, and the single or paired single-piece stirrups are conveyed to a top plate reinforcement cage welding mechanism; straightening and shearing a full-length reinforcement raw material, and conveying the full-length reinforcement raw material to a top plate reinforcement cage welding mechanism; and the top plate reinforcement cage welding mechanism is used for welding the single stirrups and the full-length ribs to form the precast beam top plate reinforcement cage. Compared with the prior art, the manufacturing method of the precast beam top plate reinforcement cage effectively solves the problems that the stirrup production speed and the reinforcement cage assembly speed are not coordinated, and the stirrup transfer and preparation efficiency is low.

Description

Technical Field

[0001] This invention relates to the field of precast beam construction technology, and more specifically, to a method for manufacturing a reinforcing cage for the top slab of a precast beam. Background Technology

[0002] The existing production methods for precast beam (e.g., T-beam) top slab reinforcement cages suffer from inefficiency, poor coordination, and insufficient precision. Specifically: First, a mismatch exists between the production speed of individual stirrups and the final assembly speed of the reinforcement cage, easily creating bottlenecks in the production process and impacting overall production efficiency. Second, the transfer and preparation of stirrups from the production stage to the assembly stage often requires significant manpower and time for stacking and rearranging, increasing production costs and time. Third, during the assembly of the precast beam top slab reinforcement cage, welding long continuous bars to numerous stirrups is cumbersome and time-consuming, and it's difficult to ensure that each stirrup is precisely positioned at the welding point, thus affecting welding quality and the precision of the final product. These problems collectively restrict the automated and efficient production of precast beam top slab reinforcement cages. Summary of the Invention

[0003] The purpose of this invention is to provide a method for manufacturing a precast beam top slab reinforcement cage, which has the advantages of solving the problem of mismatch between the production speed of stirrups and the assembly speed of reinforcement cage, reducing manual operation steps, and improving welding positioning accuracy.

[0004] This invention provides a method for manufacturing a precast beam top slab reinforcement cage, comprising: Step S1: After straightening, cutting, and bending the top and bottom reinforcement materials respectively, they are welded to form a single stirrup. Step S2: The single stirrup is transferred to the stirrup buffer mechanism by the robot for temporary storage, so as to balance the stirrup production speed and the steel cage forming speed. Step S3: Use the stirrup transfer and stacking mechanism to grab multiple sets of buffered single stirrups at once and transfer them to the stirrup single-piece positioning and conveying mechanism. Step S4: Multiple single stirrups are closely arranged in the single stirrup positioning and conveying mechanism, and the single or paired single stirrups are conveyed to the top plate steel cage welding mechanism through the single stirrup positioning and conveying mechanism. Step S5: After straightening and cutting, the long reinforcing bar material is conveyed to the top plate reinforcing cage welding mechanism; In step S6, the top slab reinforcement cage welding mechanism welds the single stirrup to the continuous reinforcement bar to form a precast beam top slab reinforcement cage.

[0005] Optionally, in step S1, the top reinforcement material is 16mm wire rod, the bottom reinforcement material is 12mm wire rod, and the top and bottom reinforcement are welded together to form the single stirrup; in step S2, the robot transfers the single stirrup into the slot of the stirrup buffer mechanism.

[0006] Optionally, in step S2, the stirrup caching mechanism includes multiple trolleys with slots, which are driven by servo motors to reciprocate along a track to store the single stirrups at specific intervals.

[0007] Optionally, in step S5, after the continuous reinforcing bar is laid out, straightened, and cut, it is divided into upper and lower layers by the material support device, clamped by the claws of the wire feeding mechanism and fed into the conveying wheel, and then conveyed to the top plate steel cage welding mechanism under the support of the continuous reinforcing bar support and positioning device.

[0008] Optionally, multiple through-rib support and positioning devices are arranged at intervals on the conveying path to ensure that the through-rib passes smoothly through the single stirrup and accurately reaches the welding position.

[0009] Optionally, in step S3, the stirrup transfer and stacking mechanism includes a clamping device, a vertical moving system, and a horizontal moving system. The clamping device includes a clamping cylinder, a clamping movable plate with special tooth grooves, and a clamping fixed plate. The clamping movable plate is driven by the clamping cylinder to cooperate with the clamping fixed plate to clamp the single stirrup. Then, the transfer of the single stirrup is realized by the vertical moving system and the horizontal moving system.

[0010] Optionally, in step S6, the welding mechanism for the top slab reinforcement cage includes a frame, a docking gripper, a welding assembly, and a continuous reinforcement traction mechanism; the welding and forming process of the precast beam top slab reinforcement cage includes: Step S61: The docking jaws clamp and position a single stirrup piece. The continuous bar traction mechanism switches to traction mode to clamp multiple continuous bars and traction multiple continuous bars to move a preset distance along their extension direction until the multiple continuous bars are aligned with multiple welding points of the single stirrup piece. The welding assembly moves along the multiple welding points of the single stirrup piece and sequentially welds the multiple welding points to the corresponding continuous bars to complete the welding of the single stirrup piece to multiple continuous bars. Step S62: After a single stirrup is welded, the docking jaws are released and reset, the traction mechanism switches to the no-load reset state and moves in the opposite direction by a preset distance, and then step S61 is repeated to weld the next single stirrup. Step S63: Repeat step S62 until the welding of multiple single stirrups and multiple continuous reinforcing bars is completed, so as to achieve the overall welding and forming of the precast beam top plate reinforcement cage.

[0011] Optionally, in step S1, the top rib is processed by the cutting machine and then picked up by the top rib feeding mechanism and bent by the top rib bending mechanism, and the bottom rib is processed by the straightening and cutting device and then picked up by the bottom rib feeding mechanism and bent by the bottom rib bending mechanism.

[0012] Optionally, after the welding of the precast beam top slab reinforcement cage is completed, the method for manufacturing the precast beam top slab reinforcement cage further includes: Step S7: The precast beam top slab reinforcement cage, which has been welded, is received and transported by the top slab reinforcement cage support mechanism.

[0013] Optionally, in step S7, the top plate steel cage support mechanism adjusts the height of the support rollers by using a top plate type elevator and adjusts the angle of the support rollers by using a bolt hole type elevator to adapt to steel cages of different specifications.

[0014] The present invention provides a method for manufacturing a precast beam top slab reinforcement cage, which, compared with related technologies, has the following beneficial effects, but is not limited to: The precast beam top slab reinforcement cage manufacturing method of this invention includes a stirrup buffer mechanism, which is a device for temporarily storing single stirrups to balance the production speed, mainly to achieve dynamic matching between the stirrup production speed and the reinforcement cage forming speed. A stirrup transfer and stacking mechanism is a mechanism capable of grabbing multiple sets of single stirrups at once, mainly to improve the efficiency of stirrup transfer and preparation. A single stirrup positioning and conveying mechanism is a device that achieves orderly arrangement and precise delivery of stirrups to the welding point through physical constraints. Its slots can be fixed grooves or adjustable guide rails, and the sorting forks can be pneumatic or electromagnetic forks, mainly to ensure the positional stability of single stirrups during the conveying process. Step-by-step traction of continuous reinforcement refers to the process of welding continuous reinforcement by traction in a step-by-step manner. This can be achieved using a servo motor-driven roller system or a chain traction device, such as a precision stepping system based on encoder feedback, mainly to achieve automated insertion and step-by-step welding of continuous reinforcement. Therefore, through the systematic integration of the above-mentioned technical means, this invention effectively solves the problems of the mismatch between the production speed of stirrups and the assembly speed of steel cages, the low efficiency of stirrup transportation and preparation, and the insufficient positioning accuracy when the continuous reinforcement passes through the stirrups. Specifically, the dynamic storage mechanism of the stirrup buffer mechanism eliminates the production bottleneck, the batch processing capability of the stirrup transportation and stacking mechanism reduces the time for manual intervention, the physical constraints of the stirrup single-piece positioning and conveying mechanism ensure the accuracy of the welding point, and the rhythm control of the step-by-step traction continuous reinforcement simplifies the assembly process, thereby realizing the efficient and precise manufacturing of the precast beam top slab reinforcement cage. Attached Figure Description

[0015] Figure 1 This is a flowchart illustrating the manufacturing method of the precast beam top slab reinforcement cage according to an embodiment of the present invention; Figure 2This is a schematic diagram of the precast beam top slab reinforcement cage according to an embodiment of the present invention.

[0016] Explanation of reference numerals in the attached figures: 1. Single stirrup; 2. Continuous reinforcement. Detailed Implementation

[0017] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0018] In the description of this invention, the orientations or positional relationships indicated by terms such as "up," "down," "left," "right," "top," "bottom," "front," "back," "inner," and "outer" are based on the orientations or positional relationships shown in the accompanying drawings and are used only for the convenience of describing this invention. They are not intended to indicate or imply that the device referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as limiting the scope of protection of this invention.

[0019] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0020] In the description of this specification, references to terms such as "embodiment," "one embodiment," and "one implementation" indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or implementation is included in at least one embodiment or implementation of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or implementation. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or implementations.

[0021] like Figures 1 to 2 As shown, the method for manufacturing the precast beam top slab reinforcement cage according to an embodiment of the present invention includes: Step S1: After straightening, cutting, and bending the top and bottom reinforcement materials respectively, they are welded to form a single stirrup. Step S2: The single stirrup is transferred to the stirrup buffer mechanism by the robot for temporary storage, so as to balance the stirrup production speed and the steel cage forming speed. Step S3: Use the stirrup transfer and stacking mechanism to grab multiple sets of buffered single stirrups at once and transfer them to the stirrup single-piece positioning and conveying mechanism. Step S4: Multiple single stirrups are closely arranged in the single stirrup positioning and conveying mechanism, and the single or paired single stirrups are conveyed to the top plate steel cage welding mechanism through the single stirrup positioning and conveying mechanism. Step S5: After straightening and cutting, the long reinforcing bar material is conveyed to the top plate reinforcing cage welding mechanism; In step S6, the top slab reinforcement cage welding mechanism welds the single stirrup to the continuous reinforcement bar to form a precast beam top slab reinforcement cage.

[0022] In this embodiment, in conjunction with the appendix Figure 1 To be continued Figure 2 As shown, the stirrup buffer mechanism is a device used to temporarily store single stirrups to balance the production speed, mainly to achieve dynamic matching between the stirrup production speed and the rebar cage forming speed. The stirrup transfer and stacking mechanism is a mechanism capable of grabbing multiple sets of single stirrups at once, mainly to improve the efficiency of stirrup transfer and preparation. The single stirrup positioning and conveying mechanism is a device that realizes the orderly arrangement and delivery of stirrups to the stirrup buffer mechanism. Thus, through the systematic integration of the above technical means, this invention effectively solves the problems of mismatch between stirrup production speed and rebar cage assembly speed, low efficiency of stirrup transfer and preparation, and insufficient positioning accuracy when continuous bars pass through stirrups. Specifically, the dynamic storage mechanism of the stirrup buffer mechanism eliminates the production bottleneck, and the batch processing capability of the stirrup transfer and stacking mechanism reduces manual intervention time, thereby achieving efficient and precise manufacturing of precast beam top slab rebar cages.

[0023] Specifically, the method for manufacturing the precast beam top slab reinforcement cage achieves efficient coordination and precise control of the production process through systematic integration of automated equipment and process optimization. In the single-stirrup manufacturing stage, the top and bottom reinforcement materials are straightened, sheared, and bent before being welded to form single stirrups. The independent pretreatment of the top and bottom reinforcement materials ensures the geometric accuracy and structural consistency of the single stirrups, avoiding deformation risks during overall processing and laying a standardized foundation for subsequent automated processes. Furthermore, in the transfer and coordination stage, a robot transfers the single stirrups to a stirrup buffer mechanism for temporary storage. This buffer mechanism dynamically adjusts the storage capacity to achieve real-time matching between the stirrup production speed and the reinforcement cage forming speed, effectively eliminating production bottlenecks caused by speed differences. Preferably, the robot can be a six-axis industrial robot with an end effector equipped with an adaptive gripping device to stably grasp the single stirrups and accurately place them into the slots of the buffer mechanism, thereby reducing waiting time for manual intervention.

[0024] In the stirrup stacking and positioning stage, the stirrup transfer and stacking mechanism grabs multiple sets of buffered single stirrups at once and transfers them to the single stirrup positioning and conveying mechanism. This operation can significantly shorten the transfer cycle and improve material preparation efficiency through the synergy of the clamping device and the moving system. For example, in practical applications, the stirrup transfer and stacking mechanism can use a servo-driven horizontal moving system in conjunction with a pneumatic clamping device to achieve synchronous grabbing and transfer of multiple sets of single stirrups. In the continuous bar preparation stage, the continuous bar raw material is straightened and sheared before being conveyed to the stirrup buffering mechanism. This pretreatment process ensures the straightness and dimensional accuracy of the continuous bar, providing a reliable prerequisite for subsequent precise docking with single stirrups.

[0025] This method effectively solves the problem of the mismatch between the production speed of stirrups and the assembly speed of steel cages. The production rhythm is balanced by the dynamic adjustment of the buffer mechanism. At the same time, the efficiency of stirrup transportation and preparation is improved. Grabbing multiple sets of single stirrups at one time avoids the stacking chaos of manual placement. Ultimately, it realizes the efficient and precise manufacturing of precast beam top slab steel cages.

[0026] Optionally, in step S1, the top reinforcement material is 16mm wire rod, the bottom reinforcement material is 12mm wire rod, and the top and bottom reinforcement are welded together to form the single stirrup; in step S2, the robot transfers the single stirrup into the slot of the stirrup buffer mechanism.

[0027] In this embodiment, the top reinforcement material refers to the steel bar material used to form the top of the stirrup, which can be made of 16mm diameter wire rod. Its purpose is to provide sufficient rigidity to withstand straightening and bending without deformation, avoiding structural instability due to excessive thinness or welding difficulties caused by excessive thickness. The bottom reinforcement material refers to the steel bar material used to form the bottom of the stirrup, which can be made of 12mm diameter wire rod. Its purpose is to form a reasonable proportional relationship with the top reinforcement, ensuring uniform heat distribution during welding and reducing stress concentration and weld cracking risks caused by material differences. The top and bottom reinforcements are welded together to form a single stirrup, meaning that the top and bottom reinforcements are fixedly connected to form a U-shaped structure using arc welding or resistance welding. This aims to ensure the overall geometric stability and structural strength consistency of the single stirrup. The robot transfer to the slot of the stirrup buffer mechanism refers to using a robotic arm in conjunction with a clamping device to grab the single stirrup and place it in the designated position of the buffer mechanism. This aims to achieve automated transfer and reduce positioning deviations caused by manual intervention.

[0028] Specifically, this invention limits the raw material specifications of the top and bottom reinforcement bars, ensuring that the top reinforcement bars maintain the required stiffness after straightening and bending. The matching of the bottom reinforcement bar size with the top reinforcement bar size ensures uniform heat distribution during welding, thereby reducing material strength mismatch and dimensional deviation. The standardized size of the single stirrup bar formed after welding enables the robot to accurately grasp and transport it into the slot of the stirrup bar buffer mechanism. The slot design adapts to the standard size to ensure that the stirrup bars are neatly arranged, effectively balancing the stirrup bar production speed and the steel cage forming speed.

[0029] Optionally, in step S2, the stirrup caching mechanism includes multiple trolleys with slots, which are driven by servo motors to reciprocate along a track to store the single stirrups at specific intervals.

[0030] In this embodiment, the trolley with slots refers to a mobile carrier used for temporary storage of single stirrups. The slots can be designed as groove structures adapted to the contours of the single stirrups, such as U-shaped or V-shaped grooves. Their purpose is to physically constrain and fix the position of the single stirrups, preventing displacement or deformation during storage. The servo motor drive can be understood as a closed-loop controlled motor system, which can be implemented using a DC servo motor or an AC servo motor in conjunction with a position feedback device. Its purpose is to provide precise speed and position adjustment capabilities, ensuring the repeatability of the trolley's movement. Reciprocating movement along the track specifically refers to the trolley's linear reciprocating motion on a fixed guide path. This can be achieved using linear guide rails or roller-type track structures, aiming to maintain the stability of the trolley's trajectory. Specific spacing storage refers to the single stirrups being arranged at a preset fixed distance in the buffer mechanism. This can be determined based on the design parameters of the precast beam top slab reinforcement cage, aiming to strictly correspond to the positioning requirements of subsequent processes.

[0031] Specifically, in step S2, when the robot transfers a single stirrup to the stirrup buffer mechanism, multiple trolleys with slots are driven by servo motors to move along the track to the receiving position, where the single stirrup is placed into the slot. The servo motors precisely control the trolleys' moving speed and stopping position according to the production rhythm, ensuring that the single stirrups are stored at specific intervals. This design achieves automated storage and retrieval and dynamic scheduling of single stirrups, eliminating manual intervention and dynamically matching the stirrup production speed with the rebar cage forming speed. It also ensures the accuracy of the storage position, providing a reliable foundation for subsequent robot transfer and welding positioning.

[0032] Optionally, in step S5, after the continuous rib is laid out, straightened, and cut, it is divided into upper and lower layers by the material support device, clamped by the claws of the wire feeding mechanism and fed into the conveying wheel, and then conveyed to the stirrup buffer mechanism under the support of the continuous rib support and positioning device.

[0033] Multiple longitudinal reinforcement support and positioning devices are arranged at intervals on the conveying path to ensure that the longitudinal reinforcement passes smoothly through the single stirrup and reaches the welding position accurately.

[0034] In this embodiment, the material support device refers to the mechanism used to orderly separate the continuous reinforcing bars into upper and lower layers. It can be implemented by using a material distribution trough or a mechanical layering device. The purpose is to achieve the orderly arrangement of the continuous reinforcing bars based on the structural requirements of the precast beam top slab reinforcement cage, and to avoid misalignment caused by mutual interference when passing through the stirrups. The clamps of the wire feeding mechanism refer to the components used to accurately clamp the continuous reinforcing bars. They can be implemented by using a pneumatic clamping unit or an electromagnetic adsorption device. The purpose is to ensure that the continuous reinforcing bars maintain a fixed posture during movement and prevent sliding or rotation caused by inertia or external forces. The continuous reinforcing bar support and positioning device refers to the support structure used to maintain the straight shape of the continuous reinforcing bars. It can be implemented by using a roller bracket or a fixed bracket. The purpose is to provide a stable support path and prevent the continuous reinforcing bars from bending and deforming during transportation.

[0035] Optionally, in step S3, the stirrup transfer and stacking mechanism includes a clamping device, a vertical moving system, and a horizontal moving system. The clamping device includes a clamping cylinder, a clamping movable plate with special tooth grooves, and a clamping fixed plate. The clamping movable plate is driven by the clamping cylinder to cooperate with the clamping fixed plate to clamp the single stirrup. Then, the transfer of the single stirrup is realized by the vertical moving system and the horizontal moving system.

[0036] In this embodiment, the stirrup transfer and stacking mechanism can span above the stirrup buffer mechanism and the stirrup single-piece positioning and conveying mechanism. After the single stirrups are welded, they are stacked in the buffer trolley, with several pieces forming a group, and parked at the waiting gripping station. The vertical moving motor starts, driving the gear shaft to move on the rack, thereby causing the lifting beam to move up and down under the guidance of the vertical linear guide rail, which in turn drives the clamping device to approach the single stirrup. The clamping movable plate and clamping fixed plate in the clamping device are designed with toothed grooves with a special tooth shape, and the toothed groove spacing is consistent with the slot holes on the buffer trolley. After multiple groups of single stirrups are inserted into the gap formed by the clamping movable plate and the clamping fixed plate, the clamping cylinder works, pushing the clamping movable plate to one side, reducing the toothed groove spacing between it and the clamping fixed plate, thereby clamping the single stirrup group. The clamping cylinder and clamping movable plate are set in multiple groups. This device can clamp a single set of stirrups individually or multiple sets together. After clamping, the vertical moving motor starts, causing the clamping device to remove the stirrup from the trolley. The horizontal moving motor reducer starts, driving the gear shaft to move on the rack, thus driving the moving beam to move horizontally under the guidance of the horizontal linear guide. Upon reaching the unloading point, the vertical moving motor starts again, driving the clamping device to place the stirrup into the designated position. The clamping cylinder operates, retracting the clamping movable plate to its original position, reducing the tooth gap between it and the clamping fixed plate, and releasing the stirrup set. This achieves automatic clamping and transport of one or more sets of stirrups. This device can grab and automatically transport multiple sets of stirrups at once, connecting the stirrup production equipment with the rebar cage production line, saving preparation time during the stacking process of single stirrups, and thus achieving efficient production of T-beam top slab rebar cages.

[0037] Optionally, in step S6, the welding mechanism for the top slab reinforcement cage includes a frame, a docking gripper, a welding assembly, and a continuous reinforcement traction mechanism; the welding and forming process of the precast beam top slab reinforcement cage includes: Step S61: The docking jaws clamp and position a single stirrup piece. The continuous bar traction mechanism switches to traction mode to clamp multiple continuous bars and traction multiple continuous bars to move a preset distance along their extension direction until the multiple continuous bars are aligned with multiple welding points of the single stirrup piece. The welding assembly moves along the multiple welding points of the single stirrup piece and sequentially welds the multiple welding points to the corresponding continuous bars to complete the welding of the single stirrup piece to multiple continuous bars. Step S62: After a single stirrup is welded, the docking jaws are released and reset, the traction mechanism switches to the no-load reset state and moves in the opposite direction by a preset distance, and then step S61 is repeated to weld the next single stirrup. Step S63: Repeat step S62 until the welding of multiple single stirrups and multiple continuous reinforcing bars is completed, so as to achieve the overall welding and forming of the precast beam top plate reinforcement cage.

[0038] In this embodiment, the docking jaws are used to clamp a single stirrup; the welding assembly is configured to move along the arrangement direction of multiple preset welding points, which are the positions where the single stirrup clamped by the docking jaws is welded to multiple continuous bars; the continuous bar traction mechanism includes a clamping state and an unloaded reset state. In the clamping state, the continuous bar traction mechanism clamps multiple continuous bars a preset distance along the conveying direction of the continuous bars. In the unloaded reset state, the continuous bar traction mechanism moves a preset distance away from the conveying direction of the continuous bars. The preset distance is equal to the straight-line distance between two adjacent single stirrups in the finished steel cage.

[0039] Specifically, the frame can be formed by welding, casting, or assembling steel, for example, using a rectangular frame structure or a truss structure. The frame as a whole can be a hexagonal frame structure, with a product channel formed in the middle of its length. The docking grippers can include pneumatic grippers, hydraulic grippers, or electric grippers, and their gripping action is controlled by a drive device. For example, a solenoid valve can be used to switch the air path to achieve the opening and closing action of the pneumatic grippers, or a motor can drive a gear and rack mechanism to achieve the movement of the grippers. The docking grippers are mounted on the frame and located at the entrance end of the frame. The welding assembly, or welding mechanism, can move along a preset welding point via a slide rail coupled with a linear motor, lead screw drive, or synchronous belt drive, combined with... Figure 2 As shown, the shape of the single stirrup 1 is similar to an inverted trapezoid. The longer side of the inverted trapezoid needs to be welded to multiple continuous reinforcing bars 2, and the two waist sides of the inverted trapezoid also need to be welded to multiple continuous reinforcing bars 2. Thus, multiple welding points are formed on the longer side, spaced apart along the direction of the longer side, and multiple welding points are also distributed on each waist side. The clamping state and no-load reset state of the continuous reinforcing bar traction mechanism can be achieved by mechanical linkage mechanism, cylinder drive, or motor drive. For example, a double-acting cylinder can be used to push the gripper to complete the clamping and releasing action, and the movement distance can be controlled by a limit switch.

[0040] In this embodiment, the welding process of the top slab reinforcement cage welding mechanism is as follows: The frame is fixed to provide stable support and aligned with the conveyor line. A single stirrup is first conveyed to the entrance end of the frame, and then the docking jaws clamp the first single stirrup, keeping it in a stable state to ensure the stability of subsequent welding. During the clamping process, the continuous reinforcement traction mechanism is in an unloaded reset state. Then, multiple continuous reinforcement bars are conveyed to the entrance end of the frame. At this time, the continuous reinforcement traction mechanism switches to a clamping state. In the clamping state, the continuous reinforcement traction mechanism clamps the continuous reinforcement bars along the conveying direction for a preset distance, which can be the straight-line distance between two adjacent single stirrups in the finished reinforcement cage. Under the traction of the continuous reinforcement traction mechanism, multiple continuous reinforcement bars are transported to the area enclosed by the first single stirrup, and each continuous reinforcement bar is accurately aligned with the corresponding welding point on the first single stirrup. Finally, the welding assembly moves along multiple preset welding points of the first single-piece stirrup, welding multiple welding points sequentially to complete the welding of the first single-piece stirrup to multiple continuous reinforcing bars. After the first single-piece stirrup is welded, the butt clamp releases its grip on the first single-piece stirrup and resets. The continuous reinforcing bar traction mechanism switches to an unloaded reset state and moves a preset distance away from the conveying direction of the continuous reinforcing bars to reset. After the butt clamps and conveys the second single-piece stirrup, the continuous reinforcing bar traction mechanism switches back to the clamping state and pulls multiple continuous reinforcing bars along the conveying direction to move another preset distance. Then, the welding assembly moves along multiple preset welding points of the second single-piece stirrup, welding multiple welding points sequentially to complete the welding of the second single-piece stirrup to multiple continuous reinforcing bars. The above process is repeated until the welding of the reinforcing cage is completed.

[0041] Therefore, in this embodiment, the docking jaws, welding components, and continuous rib traction mechanism are all connected to the frame, which provides a stable support platform to ensure stable operation of the welding process. The docking jaws grip the conveyed stirrup pieces, improving the transfer efficiency of the stirrup pieces. During welding, the docking jaws fix the position of the stirrup pieces, preventing them from shifting and ensuring accurate positioning of the welding points, thus guaranteeing welding quality. The welding components move along the arrangement direction of multiple preset welding points, automatically positioning and performing welding operations, reducing manual intervention and improving welding consistency and efficiency. The continuous rib traction mechanism, in the clamping state, clamps the continuous ribs a preset distance along the conveying direction, ensuring that the welding position of each continuous rib is accurately aligned with the welding point on each stirrup piece, guaranteeing the welding accuracy of multiple continuous ribs. In the no-load reset state, the continuous rib traction mechanism moves a preset distance away from the conveying direction of the continuous ribs, achieving rapid reset. In this way, during the welding process, it can be ensured that each stirrup can be precisely welded to multiple continuous reinforcing bars, forming a continuous and efficient welding process, thereby improving the welding accuracy and efficiency of the reinforcing cage, and solving the problems of poor accuracy and low efficiency caused by inaccurate positioning and cumbersome operation in traditional reinforcing cage welding.

[0042] In other embodiments, the rib pulling mechanism may include a rib gripper, a sliding track, and a drive structure. The drive structure is connected to the frame, the sliding track is connected to the frame and extends along the conveying direction, and there are multiple rib grippers, each gripper gripping one rib. The connecting end of the rib gripper is slidably connected to the sliding track. The drive structure is used to drive the multiple rib grippers to slide back and forth along the sliding track, and the sliding distance is a preset distance. The gripping end of the rib gripper grips the rib in the clamping state and releases the gripping of the rib in the no-load reset state.

[0043] In the no-load reset state, the clamping end of the through-rib gripper is in the open state. The drive structure drives the through-rib gripper to move away from the frame and away from the conveying direction along the sliding track and stop at any position. In this state, the through-rib gripper can wait to clamp the through-rib.

[0044] In the clamping state, the clamping ends of the continuous rib grippers are closed, with each gripper holding one continuous rib. Then, the drive structure moves the grippers along the sliding track away from the frame, i.e., towards the conveying direction, aligning the welding position on each continuous rib with its corresponding welding point. Furthermore, the end of the continuous rib facing the frame is the starting end, and a certain distance is maintained between the clamping position of the gripper and the starting end of the continuous rib to avoid interference with the welding point. After each stirrup is welded individually, the machine switches to an unloaded reset state, releasing the grippers to prevent reverse dragging or friction damage to the continuous rib during the reset phase. After reset, the continuous rib is clamped again until the welding of one rebar cage is completed.

[0045] Thus, by extending the sliding track along the conveying direction and firmly connecting it to the frame, and by slidably connecting the sliding track to the continuous reinforcement clamp, a precise linear guide path is provided for the continuous reinforcement clamp, ensuring the accuracy of the continuous reinforcement traction direction. The drive structure is directly fixed to the frame, and its output power is controlled to drive the continuous reinforcement clamp to slide back and forth along the sliding track, with the sliding distance equal to a preset distance. This further ensures that the moving distance of the continuous reinforcement clamp is consistent with the linear distance between each pair of stirrups in the reinforcing cage, reducing traction errors. This allows for precise control of the conveying distance and position of the continuous reinforcement during welding, improving welding accuracy and solving the problem of insufficient accuracy caused by positioning deviations in traditional reinforcing cage welding.

[0046] Optionally, in step S1, the top rib is processed by the cutting machine and then picked up by the top rib feeding mechanism and bent by the top rib bending mechanism, and the bottom rib is processed by the straightening and cutting device and then picked up by the bottom rib feeding mechanism and bent by the bottom rib bending mechanism.

[0047] In this embodiment, the top rib laying mechanism refers to the device for automatically grabbing and transferring the top ribs, which can be implemented using a robotic arm or conveyor belt system, with the aim of reducing the time consumption and positional deviation of manual handling; the top rib bending mechanism refers to the equipment for bending and shaping the top ribs, which can be implemented using a hydraulic bending machine or a bending machine driven by a servo motor, with the aim of ensuring the stability of the bending angle; the bottom rib laying mechanism and the top rib laying mechanism are the same mechanism, and the bottom rib bending mechanism and the top rib bending mechanism are the same mechanism.

[0048] Specifically, this invention achieves a fully automated processing flow by seamlessly connecting the processing, transfer, and bending stages of the top and bottom reinforcing bars. After precise cutting by a cutting machine, the top reinforcing bar is automatically picked up by a top reinforcing bar feeding mechanism and transferred to a top reinforcing bar bending mechanism for bending and shaping. Simultaneously, the bottom reinforcing bar is straightened and cut in an integrated manner by a straightening and cutting device, and then picked up by a bottom reinforcing bar feeding mechanism and transferred to a bottom reinforcing bar bending mechanism for bending. The precise coordination of these steps ensures a high degree of consistency in size and shape between the top and bottom reinforcing bars, providing a reliable foundation for the welding of single-piece stirrups, thereby effectively eliminating the uncertainties caused by manual intervention.

[0049] Optionally, after the welding of the precast beam top slab reinforcement cage is completed, the method for manufacturing the precast beam top slab reinforcement cage further includes: Step S7: The precast beam top slab reinforcement cage, which has been welded, is received and transported by the top slab reinforcement cage support mechanism.

[0050] In step S7, the top plate steel cage support mechanism adjusts the height of the support rollers by using a top plate type elevator and adjusts the angle of the support rollers by using a bolt hole type elevator to adapt to steel cages of different specifications.

[0051] In this embodiment, the top-plate type lifting platform refers to a lifting device for vertical adjustment, which can be implemented using a hydraulic cylinder, electric push rod, or screw mechanism. Its purpose is to accurately control the vertical position of the rollers according to the actual height parameters of the reinforcing cage, avoiding problems such as unstable frame placement or equipment interference caused by height differences. The bolt-hole type lifting platform can be understood as a mechanism that achieves angle adjustment through bolt hole cooperation. It can be implemented using a pin shaft and hole groove cooperation, gear rack, or linkage mechanism. Its purpose is to fine-tune the angle of the support rollers according to the geometric shape changes of the reinforcing cage, ensuring that the frame maintains the correct posture during transportation and preventing twisting or displacement caused by angle mismatch.

[0052] Specifically, by adjusting the top plate lifting machine according to the different priorities of each finished product in advance, the height position of the support roller is determined to be able to contact the support position. Then, according to the angle between the bottom steel bar of the steel cage and the support roller, the angle of the support roller is adjusted by adjusting the bolt hole lifting machine. After the adjustment is completed, the welded top plate steel cage can be received.

[0053] While the present invention has been disclosed above, its scope of protection is not limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the present invention, and all such changes and modifications will fall within the scope of protection of the present invention.

Claims

1. A method for manufacturing a precast beam top slab reinforcement cage, characterized in that, The application relates to a prefabricated beam top plate steel cage welding device and a welding method thereof. Step S1: top rib raw materials and bottom rib raw materials are respectively subjected to straightening, shearing and bending treatment, and then are welded to form single-piece stirrups; Step S2: the single-piece stirrups are transferred to a stirrup buffer mechanism by a robot to temporarily store the single-piece stirrups, so as to balance the production speed of the stirrups and the forming speed of the steel cage; Step S3: a stirrup transfer stacking mechanism is used to one-time grab a plurality of groups of the single-piece stirrups stored in the buffer mechanism, and then the single-piece stirrups are transferred to a single-piece stirrup positioning conveying mechanism; Step S4: a plurality of the single-piece stirrups are closely arranged in the single-piece stirrup positioning conveying mechanism, and then the single-piece stirrups are conveyed to a top plate steel cage welding mechanism by the single-piece stirrup positioning conveying mechanism; Step S5: after the full-length rib raw materials are subjected to straightening and shearing, the full-length rib raw materials are conveyed to the top plate steel cage welding mechanism; Step S6: the top plate steel cage welding mechanism welds the single-piece stirrups and the full-length ribs to form a prefabricated beam top plate steel cage.

2. The method of fabricating a precast beam topping reinforcement cage of claim 1, wherein, In step S1, the top rib raw materials adopt 16mm coil steel, and the bottom rib raw materials adopt 12mm coil steel; the top rib and the bottom rib are integrally formed into the single-piece stirrups by welding; in step S2, the single-piece stirrups are transferred to the card slot of the stirrup buffer mechanism by the robot.

3. The method of fabricating a precast beam topping reinforcement cage of claim 1, wherein, In step S2, the stirrup buffer mechanism comprises a plurality of trolleys with card slots; the trolleys are driven to move back and forth along the track by servo motors, and the single-piece stirrups are stored at specific intervals.

4. The method of fabricating a precast beam topping reinforcement cage of claim 1, wherein, In step S5, after the full-length ribs are unwound, straightened and sheared, the full-length ribs are divided into upper and lower layers by a material supporting device, are clamped by the clamping jaws of a wire feeding mechanism and are fed into a conveying wheel, and then the full-length ribs are conveyed to the top plate steel cage welding mechanism under the support of a full-length rib supporting and positioning device.

5. The method of fabricating a precast beam topping reinforcement cage of claim 4 wherein, The full-length rib supporting and positioning devices are arranged at intervals on a conveying path, so as to ensure that the full-length ribs smoothly pass through the single-piece stirrups and accurately reach the welding position.

6. The method of fabricating a precast beam topping reinforcement cage of claim 1, wherein, In step S3, the stirrup transfer stacking mechanism comprises a clamping device, a vertical moving system and a horizontal moving system; the clamping device comprises a clamping cylinder, a clamping movable plate and a clamping fixed plate with special tooth grooves; the single-piece stirrups are clamped by the clamping cylinder driving the clamping movable plate and the clamping fixed plate, and then the single-piece stirrups are transferred by the vertical moving system and the horizontal moving system.

7. The method of fabricating a precast beam topping reinforcement cage of claim 1 wherein, In step S6, the top plate steel cage welding mechanism comprises butt clamping jaws, a welding assembly and a full-length rib traction mechanism; the welding and forming process of the prefabricated beam top plate steel cage comprises the following steps: Step S61: the butt clamping jaws clamp and position a single-piece stirrup; the full-length rib traction mechanism is switched to a traction state to clamp and traction a plurality of full-length ribs to move a preset distance along the extension direction of the full-length ribs until the plurality of full-length ribs are aligned with a plurality of welding points of the single-piece stirrup; the welding assembly moves along the plurality of welding points of the single-piece stirrup and sequentially welds the plurality of welding points and the corresponding full-length ribs to complete the welding of the single-piece stirrup and the plurality of full-length ribs. Step S62, after the welding of a single stirrup is completed, the clamping jaw is released and reset, the traction mechanism is switched to the empty reset state and moves reversely by a preset distance, and then step S61 is repeatedly executed to realize the welding of the next single stirrup; Step S63, step S62 is repeatedly executed until the welding of multiple single stirrups and multiple longitudinal stirrups is completed, so as to realize the overall welding forming of the precast beam top reinforcement cage.

8. The method of fabricating a precast beam topping reinforcement cage of claim 1, wherein, In step S1, the top stirrup is processed by a cutting machine and then grabbed by a top stirrup distribution mechanism to a top stirrup bending mechanism for bending, and the bottom stirrup is processed by a straightening and cutting device and then grabbed by a bottom stirrup distribution mechanism to a bottom stirrup bending mechanism for bending.

9. The method of fabricating a precast beam topping reinforcement cage of claim 1, wherein, After the welding of the precast beam top reinforcement cage is completed, the method for manufacturing the precast beam top reinforcement cage further comprises: Step S7, the precast beam top reinforcement cage welded is received and transported by a top reinforcement cage supporting mechanism.

10. The method of fabricating a precast beam topping reinforcement cage of claim 9, wherein, In step S7, the top reinforcement cage supporting mechanism adjusts the height of the supporting roller by a top plate type elevator and adjusts the angle of the material supporting roller by a bolt hole type elevator, so as to adapt to different specifications of the reinforcement cage. In step S1, the top stirrup is processed by a cutting machine and then grabbed by a top stirrup distribution mechanism to a top stirrup bending mechanism for bending, and the bottom stirrup is processed by a straightening and cutting device and then grabbed by a bottom stirrup distribution mechanism to a bottom stirrup bending mechanism for bending. After the welding of the precast beam top reinforcement cage is completed, the method for manufacturing the precast beam top reinforcement cage further comprises: Step S7, the precast beam top reinforcement cage welded is received and transported by a top reinforcement cage supporting mechanism. In step S7, the top reinforcement cage supporting mechanism adjusts the height of the supporting roller by a top plate type elevator and adjusts the angle of the material supporting roller by a bolt hole type elevator, so as to adapt to different specifications of the reinforcement cage.

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