Automatic positioning and adjustment method for synchronous welding of reinforcing cages

Abstract

This invention relates to the field of steel cage processing equipment in tunnel excavation, and in particular to an automatic positioning and adjustment method for synchronous welding of steel cages. It aims to solve the problems of low positioning accuracy, low construction efficiency, deformation during construction, and poor final installation accuracy in the hoisting and positioning process of multiple rows of steel mesh in existing technologies. This invention includes the following steps: determining installation dimensions; establishing constraints for step-by-step installation; synchronous measurement; welding; secondary measurement; supplementary welding and correction; and hoisting and unloading. The advantages are: firstly, it ensures uniform and stable installation of multiple rows of steel mesh with multiple design dimensions; secondly, it overcomes the difficulty of deformation during installation, realizing an automatic positioning and adjustment method that simultaneously positions and corrects the mesh, resulting in high parallelism and end alignment of the finished product. It also possesses good adaptability, meeting the installation requirements of multiple rows of steel mesh of different specifications.

Description

Technical Field

[0001] This invention relates to the field of automatic positioning and adjustment methods for synchronous welding of reinforcing cages, and in particular to an automatic positioning and adjustment method for synchronous welding of reinforcing cages. Background Technology

[0002] In tunnel construction, there are relatively few cases of welded steel reinforcement cages; they are usually assembled manually. The installation quality directly affects the overall strength and stability of the structure. Currently, the installation of multi-row steel mesh mainly relies on manual labor in conjunction with conventional lifting equipment, which has many drawbacks: during manual hoisting, multi-row steel mesh is prone to misalignment and uneven spacing, leading to significant problems in subsequent welding.

[0003] Further positioning requires multiple people to repeatedly measure and adjust using simple measuring tools, which not only consumes a lot of manpower and resources, but also makes it difficult to guarantee the parallelism and splicing accuracy between multiple rows of mesh panels; the end alignment error of adjacent mesh panels is relatively large, affecting the integrity of the overall structure; at the same time, manual operation is labor-intensive, and the safety risks are high when working at heights or installing large mesh panels. There are problems of low efficiency, poor accuracy, and insufficient safety in the hoisting and positioning of multi-row steel mesh panels. Moreover, the applicant discovered through years of frontline work that, in current technology, errors in the processing of rebar supports often arise gradually in each step of the process, and these errors accumulate iteratively. This pattern makes it difficult for technicians to detect, leading to situations where, when the final error becomes too large, it is difficult to reverse engineer and correct it, thus affecting the final product's processing accuracy. Summary of the Invention

[0004] The purpose of this invention is to solve the defects of low positioning accuracy, low construction efficiency, and high labor intensity in the hoisting and positioning process of multi-row steel mesh in the prior art, and to provide a method that can realize automated hoisting of multi-row steel mesh and at the same time meet the requirement of uniform and stable installation between multiple rows of steel mesh under multiple design dimensions.

[0005] The specific solution of this invention is: to design an automatic positioning and adjustment method for synchronous welding of reinforcing cages, comprising the following steps: (1) Determine the installation dimensions: This includes determining the outline dimensions of the steel cage installation based on the design drawings, determining the assembly dimensions of each steel bar in the steel cage based on the design drawings, determining the spacing between single layers of the steel cage based on the strength feedback from the on-site construction, and determining the arithmetic variation of the distance between the steel bar raw materials in each single layer spacing ring based on the strength of the supporting external materials. (2) Establish constraints and install step by step: Based on the determined dimensions, install the support components, the adjustment components between the support components and the constraint components in sequence from bottom to top and from the center to both sides; bundle the raw materials to form a single ring of steel cage, install the fine adjustment components of each key node on the steel cage; design the adjacent steel cages to be fixed in pairs to form assembly A; (3) Synchronous measurement: Based on the data in step (1), in each step of step (2), the spacing, assembly dimensions and assembly offset accuracy are measured synchronously, and the data is fed back to the background central control component. The central control component issues instructions to control the power source of the adjustment component and the fine adjustment component to realize the correction of the various shapes and dimensions of the assembly A and the human assembly dimensions, forming assembly B. (4) Welding: Weld the steel bar nodes of assembly B. During the welding process, the restraining force of the restraints on assembly B is increased or decreased according to the stress requirements. The stress requirements are determined based on the design mechanics principles or evaluated based on the prefabricated finite element analysis software. After welding, assembly C is formed. (5) Secondary measurement: Using a distance detection sensor and positioning reference plate, the assembly C is dimensionally verified, and non-compliant dimensions are corrected by welding to form assembly D. (6) Lifting out of the warehouse: Release the constraints on assembly D, and use the gantry crane to apply tension from above to complete the lifting out of the warehouse of assembly D; The longitudinal reinforcement between the rings of steel cages is fixed by longitudinal steel bars. The intersection of each longitudinal steel bar with the single ring of steel cage is the fixing node. The welding process of the fixing node includes the following steps: (a) Plan: Based on the solder joint height, distinguish multiple layers of solder joints, divide them into odd-numbered layers and even-numbered layers, and further divide each layer into odd-numbered solder joints and even-numbered solder joints; (b) Welding in rounds: The first round welds odd-numbered layers with odd-numbered weld points, the second round welds even-numbered layers with even-numbered weld points, the third round welds odd-numbered layers with even-numbered weld points, and the fourth round welds even-numbered layers with odd-numbered weld points. When the welding time of a single round is less than the welding stress stabilization time of the initial weld point in that round, let it stand until the interval between two rounds of welding is not less than the welding stress stabilization time of the initial weld point. (c) Measure and add reinforcing bars: When step (b) is completed and the welding stress of the weld is stable, measure the overlap between the single rings of the steel cage. When the overlap deviation is greater than the design deviation due to the deformation of a single steel bar in a single ring, reverse traction is achieved by adding reinforcing bars. (d) Install reinforcing bars based on construction data: When encountering areas with prominent local stress during construction, reinforcing bars are added for traction and welding. Before each round of welding, the shape and position dimensions and assembly dimensions of the assembled parts are measured. The welding stress for the next round of welding is determined by referring to the dimensional measurement results in order to overcome the deformation of the previous round and the reinforcing bars.

[0006] The direction of the constraint includes the radial and axial directions along the reinforcing bar at the installation position, as well as the deflection angle of a single ring of reinforcing bar cage perpendicular to the designed installation surface and the deflection angle of a single ring of reinforcing bar cage parallel to the designed installation surface.

[0007] After step (2) and before step (4), the steel bars are fixed together with metal tie wire.

[0008] The adjustment accuracy range of the adjustment component is ±15cm and ±5 degrees; the adjustment accuracy range of the fine-tuning component is ±50mm and ±0.5 degrees.

[0009] The electronic detection instrument is fixed at the end of the steel cage and collects signals in the direction of the center.

[0010] The constraint member is a lap joint that can be detachably fixed after lapping, including a cylindrical lap joint cage that serves as the assembly center and has a width that can accommodate at least two sets of reinforcing cages, an auxiliary longitudinal positioning block for the reinforcing cage that forms a grid-like fixing device on the lap joint cage, and an axial initial positioning rail that is installed on the edge of the lap joint cage and perpendicular to the cross section of the lap joint cage.

[0011] The support member is located below the constraint member, and a pressure measuring device is provided on the contact surface between the support member and the constraint member to detect the shift in the position of the center of gravity.

[0012] At least one set of welding devices is installed on the truss, and at least two mechanical claws for hoisting raw materials and finished products are also installed on the truss; the welding devices and mechanical claws are installed at intervals, and the welding devices and mechanical claws are connected to different hoisting ropes to achieve relatively independent operation. At the same time, during the welding process, the mechanical claws on both sides form a pre-fixed structure; in the single-ring steel cage welding step, with the auxiliary positioning of the constraint members, it is also possible to achieve that after the mechanical claws and constraint members fix the raw materials, the two welding devices can simultaneously weld two weld points.

[0013] The beneficial effects of this invention are as follows: The automatic positioning and adjustment method for synchronous welding of steel cages realizes the automation of the entire installation and adjustment at each stage, reducing the labor intensity of workers; throughout the process, electronic components are simultaneously measured in real time to ensure high-precision installation and meet design requirements. On the one hand, it ensures uniform and stable installation of multiple rows of steel mesh with different design dimensions; on the other hand, it overcomes the difficulty of deformation during installation and realizes an automatic positioning and adjustment method that allows for simultaneous installation, positioning, and correction. The finished product has high parallelism and end alignment, and also has good adaptability, which can meet the installation needs of multiple rows of steel mesh with different specifications.

[0014] —The adjustment mechanism includes coarse adjustment and fine adjustment. Coarse adjustment is mainly to ensure the adjustment of different design requirements in different construction situations, while fine adjustment is for situations where the steel reinforcement raw materials themselves are deformed. With the combined effect of the two adjustment methods, the design requirements can be largely met, while reducing the requirements for raw materials and thus reducing processing costs. When fixing the longitudinal reinforcing bars, the stress relief time was planned in the welding scheme for the first time. Simultaneously, welding stress and random reinforcing bar stress were considered together, and a multi-round welding system was designed. The gap measurement dimensions were used to determine the strength of the next weld point, enabling real-time adjustments. Furthermore, the arrangement of the multiple weld points achieved the scientific and rational technical objective of stabilizing the frame structure. During assembly, the fasteners from the previous step can serve as constraints for the next step, enabling a closed-loop installation measurement correction process based on feedback from the measuring device. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of an installation structure using a single loop or single bar of steel as an example. The components in the diagram are named as follows: 1. Center; 2. Mechanical claw; 3. Welding device; 4. Support component; 5. Adjusting component; 6. Constraint component; 7. Reinforcing steel raw material; 8. Electronic testing instrument; 9. Fine-tuning device mounted on the center; 10. Fine-tuning device mounted on the constraint component. Detailed Implementation

[0016] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention. Example 1

[0017] A method for automatic positioning and adjustment of reinforcing cages during synchronous welding, see [link to relevant documentation]. Figures 1 to 2 , Includes the following steps: (1) Determine the installation dimensions: This includes determining the outline dimensions of the steel cage installation based on the design drawings, determining the assembly dimensions of each steel bar in the steel cage based on the design drawings, determining the spacing between single layers of the steel cage based on the strength feedback from the on-site construction, and determining the arithmetic variation of the distance between the steel bar raw materials in each single layer spacing ring based on the strength of the supporting external materials. (2) Establish constraints and install step by step: Based on the determined dimensions, install the support 4, the adjustment part 5 between the support 4 and the constraint 6 in sequence from the center 1 to both sides; bundle the raw materials to form a single ring of steel cage, install the fine adjustment parts of each key node on the steel cage; design the adjacent steel cages to be fixed in pairs in sequence to form assembly A; (3) Synchronous measurement: Based on the data in step (1), in each step of step (2), the spacing, assembly dimensions and assembly offset accuracy are measured synchronously, and the data is fed back to the background central control component. The central control component issues instructions to control the power source of the adjustment component 5 and the fine adjustment component to realize the correction of the various shapes and dimensions of the assembly A and the human assembly dimensions, forming the assembly B. (4) Welding: Weld the steel bar nodes of assembly B. During the welding process, the restraining force of the constraint 6 on assembly B is increased or decreased according to the stress requirements. The stress requirements are determined based on the design mechanics principle or evaluated based on the prefabricated finite element analysis software. After welding, assembly C is formed. (5) Secondary measurement: Using a distance detection sensor and a positioning reference plate, the assembly C is dimensionally verified, and non-compliant dimensions are corrected by welding to form assembly D; (6) Lifting out of the warehouse: Release the constraint of the constraint component 6 on the assembly D, and use the gantry crane to apply tension from above to complete the lifting out of the warehouse of the assembly D; The longitudinal reinforcement between the rings of steel cages is fixed by longitudinal steel bars. The intersection of each longitudinal steel bar with the single ring of steel cage is the fixing node. The welding process of the fixing node includes the following steps: (a) Plan: Based on the solder joint height, distinguish multiple layers of solder joints, divide them into odd-numbered layers and even-numbered layers, and further divide each layer into odd-numbered solder joints and even-numbered solder joints; (b) Welding in rounds: The first round welds odd-numbered layers with odd-numbered weld points, the second round welds even-numbered layers with even-numbered weld points, the third round welds odd-numbered layers with even-numbered weld points, and the fourth round welds even-numbered layers with odd-numbered weld points. When the welding time of a single round is less than the welding stress stabilization time of the initial weld point in that round, let it stand until the interval between two rounds of welding is not less than the welding stress stabilization time of the initial weld point. (c) Measure and add reinforcing bars: When step (b) is completed and the welding stress of the weld is stable, measure the overlap between the single rings of the steel cage. When the overlap deviation is greater than the design deviation due to the deformation of a single steel bar in a single ring, reverse traction is achieved by adding reinforcing bars. (d) Install reinforcing bars based on construction data: When encountering areas with prominent local stress during construction, reinforcing bars are added for traction and welding. Before each round of welding, the shape and position dimensions and assembly dimensions of the assembled parts are measured. The welding stress for the next round of welding is determined by referring to the dimensional measurement results in order to overcome the deformation of the previous round and the reinforcing bars.

[0018] The welding process is not shown in the attached diagram, but it can be understood as multiple welding points evenly distributed within a cubic space. The welding points in each round are not adjacent, allowing for equipment deformation and providing a reference for welding strength to compensate for this deformation in the next round of welding. It also considers the slow stabilization process of welding stress. The constraint direction of the constraint member 6 includes the radial and axial directions along the reinforcing bar at the installation position, as well as the deflection angle of a single ring of reinforcing bar cage perpendicular to the designed installation surface and the deflection angle of a single ring of reinforcing bar cage parallel to the designed installation surface.

[0019] After step (2) and before step (4), the steel bars are fixed together with metal tie wire.

[0020] The adjustment accuracy range of the adjustment component 5 is ±15cm and ±5 degrees; the adjustment accuracy range of the fine-tuning component is ±50mm and ±0.5 degrees.

[0021] An electronic detection instrument is fixed to the end of the steel cage and collects signals in the direction of center 1.

[0022] The constraint member 6 is a lap joint that can be detachably fixed after lapping. It includes a cylindrical lap joint cage that serves as the assembly center 1 and has a width that can accommodate at least two sets of steel cages, an auxiliary steel cage longitudinal positioning block that forms a grid-like fixing device on the lap joint cage, and an axial initial positioning rail that is installed on the edge of the lap joint cage and perpendicular to the cross section of the lap joint cage.

[0023] The support member 4 is located below the constraint member 6. A pressure measuring device is set on the contact surface between the support member 4 and the constraint member 6 to detect the offset of the center of gravity. The design point of this technology is to prevent uneven assembly density and defects in mechanical strength.

[0024] During the operation, at least one set of welding devices 3 is installed on the truss, and at least two mechanical claws 2 for hoisting raw materials and finished products are also installed on the truss. The welding devices 3 and the mechanical claws 2 are installed at intervals, and the welding devices 3 and the mechanical claws 2 are connected to different hoisting ropes to achieve relatively independent operation. At the same time, during the welding process, the mechanical claws 2 on both sides form a pre-fixed structure. In the single-ring steel cage welding step, with the auxiliary positioning of the constraint member 6, it is also possible to achieve that after the mechanical claws 2 and the constraint member 6 fix the raw materials, the two welding devices 3 can weld two weld points simultaneously. It should be noted that welding two weld points sequentially refers to the single-ring steel cage, which does not conflict with the spatial welding and non-adjacent selection of weld points mentioned above.

[0025] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for automatic positioning adjustment of synchronous welding of reinforcement cage, characterized in that, Includes the following steps: (1) Determine the installation dimensions: This includes determining the outline dimensions of the steel cage installation based on the design drawings, determining the assembly dimensions of each steel bar in the steel cage based on the design drawings, determining the spacing between single layers of the steel cage based on the strength feedback from the on-site construction, and determining the arithmetic variation of the distance between the steel bar raw materials in each single layer spacing ring based on the strength of the supporting external materials. (2) Establish constraints and install step by step: Based on the determined dimensions, install the support (4), the adjustment part (5) between the support (4) and the constraint (6) in sequence from the center (1) to both sides; the raw materials are bundled into a single ring of steel cage, and the fine adjustment parts of each key node on the steel cage are installed; the adjacent steel cages are designed to be fixed in pairs to form assembly A; (3) Synchronous measurement: Based on the data in step (1), in each step of step (2), the spacing, assembly dimensions, and assembly offset accuracy are measured synchronously, and the data is fed back to the background central control component. The central control component issues instructions to control the power source of the adjustment component (5) and the fine-tuning component to realize the correction of the various shapes and dimensions of assembly A and the human assembly dimensions, forming assembly B. (4) Welding: Weld the steel bar nodes of assembly B. During the welding process, the restraint force of the constraint (6) on assembly B is increased or decreased according to the stress requirements. The stress requirements are determined according to the design mechanics principle or evaluated according to the prefabricated finite element analysis software. After welding, assembly C is formed. (5) Secondary measurement: Using a distance detection sensor and positioning reference plate, the assembly C is dimensionally verified, and non-compliant dimensions are corrected by welding to form assembly D. (6) Lifting out of the warehouse: Release the constraint of the constraint component (6) on the assembly D, and use the gantry crane to apply tension from above to complete the lifting out of the warehouse of the assembly D.

2. The method of synchronized welding and automatic positioning adjustment of reinforcement cage according to claim 1, characterized in that: The longitudinal reinforcement between the rings of steel cages is fixed by longitudinal steel bars. The intersection of each longitudinal steel bar with the single ring of steel cage is the fixing node. The welding process of the fixing node includes the following steps: (a) Plan: Based on the solder joint height, distinguish multiple layers of solder joints, divide them into odd-numbered layers and even-numbered layers, and further divide each layer into odd-numbered solder joints and even-numbered solder joints; (b) Welding in rounds: The first round welds odd-numbered layers with odd-numbered weld points, the second round welds even-numbered layers with even-numbered weld points, the third round welds odd-numbered layers with even-numbered weld points, and the fourth round welds even-numbered layers with odd-numbered weld points. When the welding time of a single round is less than the welding stress stabilization time of the initial weld point in that round, let it stand until the interval between two rounds of welding is not less than the welding stress stabilization time of the initial weld point. (c) Measure and install reinforcing bars: When step (b) is completed and the welding stress of the weld point is stable, measure the overlap between single rings of the steel cage. When the overlap deviation is greater than the design deviation due to deformation of a single ring or single steel bar, reverse traction is achieved by adding reinforcing bars. (d) Install reinforcing bars based on construction data: When encountering areas with prominent local stress during construction, reinforcing bars are added for traction and repair welding. Before each round of welding, the shape and position dimensions and assembly dimensions of the assembled parts are measured. The welding stress for the next round of welding is determined by referring to the dimensional measurement results in order to overcome the deformation of the previous round and the reinforcing bars.

3. The method of synchronized welding and automatic positioning adjustment of reinforcement cage according to claim 1, characterized in that: The direction of the constraint (6) includes the radial and axial directions along the reinforcing bar at the installation position, as well as the deflection angle of the single ring reinforcing bar cage perpendicular to the design installation surface and the deflection angle of the single ring reinforcing bar cage parallel to the design installation surface.

4. The method of synchronized welding and automatic positioning adjustment of reinforcement cage according to claim 1, characterized in that: After step (2) and before step (4), the steel bars are fixed together with metal tie wire.

5. The method of synchronized welding and automatic positioning adjustment of reinforcement cage according to claim 1, characterized in that: The adjustment accuracy range of the adjustment component (5) is ±15cm and ±5 degrees; the adjustment accuracy range of the fine-tuning component is ±50mm and ±0.5 degrees.

6. The method of synchronized welding and automatic positioning adjustment of reinforcement cage according to claim 1, characterized in that: The electronic detection instrument involved is fixed at the end of the steel cage and collects signals in the direction of the center (1).

7. The synchronized welding automated positioning adjustment restraint for reinforcement cages of claim 1, wherein: The constraint member (6) is a lap member that can be detachably fixed after lapping, including a cylindrical lap cage that serves as the assembly center (1) and has a width that can accommodate at least two sets of steel cages, an auxiliary steel cage longitudinal positioning block that forms a grid-like fixing device on the lap cage, and an axial initial positioning rail that is installed on the edge of the lap cage and perpendicular to the cross section of the lap cage.

8. The synchronized welding automatic positioning adjustment method for reinforcement cage according to claim 1, characterized in that: The support member (4) is located below the constraint member (6), and a pressure measuring device is provided on the contact surface of the support member (4) and the constraint member (6) to detect the shift of the center of gravity.

9. The synchronized welding automatic positioning adjustment method for reinforcement cage according to claim 1, characterized in that: At least one set of welding devices (3) is installed on the truss, and at least two mechanical claws (2) for hoisting raw materials and finished products are also installed on the truss; the welding devices (3) and the mechanical claws (2) are installed at intervals, and the welding devices (3) and the mechanical claws (2) are connected to different hoisting ropes to achieve relatively independent operation. At the same time, during the welding process, the mechanical claws (2) on both sides form a pre-fixed structure; in the single-ring steel cage welding step, combined with the auxiliary positioning of the constraint member (6), it is also possible to achieve that after the mechanical claws (2) and the constraint member (6) fix the raw materials, the two welding devices (3) weld two weld points at the same time.

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