Low-friction supporting and penetrating cooperation method in reinforcement cage machining process

Abstract

The invention relates to the technical field of machining of cast-in-situ bored pile reinforcement cages, in particular to a low-friction supporting and penetrating cooperation method and system in the reinforcement cage machining process. A plurality of supporting nodes capable of being switched between rolling and locking are arranged in the axial direction of a reinforcement cage; in a rolling state, the pulley sleeve at the top of the node enables the cage body to rotate easily, and the penetrating resistance of the main rib or the sounding pipe is converted into rolling friction, so that long-distance single-point pushing is realized; a rigid fulcrum is provided in a locking state to ensure stable form of a welding section. The joint distance can be steplessly adjusted on site, the whole system can complete reinforcement cage machining without external power and manual work, machines and sites are saved, and all components are made of on-site reinforcing steel bars and standard sleeves and can be repeatedly used.

Description

Technical Field

[0001] This invention relates to the field of processing technology for drilled cast-in-place pile reinforcement cages, and particularly to methods for supporting and threading reinforcement bars during the processing of reinforcement cages; specifically, it is a low-friction support and threading coordination method during the processing of reinforcement cages. Background Technology

[0002] In the construction of bored piles, the fabrication of the reinforcing cage is one of the key steps. Traditional reinforcing cage fabrication mainly relies on rebar rigs or thread rolling machines, but these methods have the following technical problems: 1. Difficulties in structural support and rotation Traditional frame structures are fixed, and the steel cage needs to be rotated frequently during processing for welding or binding operations; Because the main reinforcement bars of the steel cage have a large diameter (usually up to 32mm) and are heavy, they are difficult to rotate manually and often require mechanical assistance such as lifting equipment, which increases construction costs and operational risks. The lack of effective low-friction rotational support structures in the existing technology results in high resistance and inconvenience in operation of the steel cage during rotation.

[0003] 2. Low efficiency in threading main reinforcement bars and sonic logging pipes. During the fabrication of the reinforcing cage, the main reinforcing bars and sonic logging tubes need to be threaded from one end of the reinforcing cage to the other. In traditional methods, due to the lack of effective guidance and drag reduction structures, the resistance during the installation process is high, requiring multiple people to work together, which is time-consuming and labor-intensive. Especially in the fabrication of long steel cages (more than 20 meters in length), the installation process has become a bottleneck restricting the overall construction progress.

[0004] 3. Poor adaptability of the support system Existing frame structures are mostly fixed and cannot be flexibly adjusted according to parameters such as the length, diameter, and weight of the steel cage; Traditional support systems have poor adaptability under different construction site conditions and are difficult to meet diverse construction needs; Traditional structures occupy a large space on the construction site, which is not conducive to the efficient use of the site.

[0005] 2.4 Challenges in Construction Efficiency and Quality Control The difficulty in rotating and threading the steel reinforcement cages resulted in low processing efficiency, affecting the overall construction progress. Manual rotation can easily cause deformation of the steel cage, affecting processing quality; Traditional methods require highly skilled operators and make it difficult to standardize and control construction quality.

[0006] Based on the above problems, the following is urgently needed in the construction of bored piles: A support method that enables low-friction rotation of steel cages, reducing manual labor intensity and improving work efficiency; A technical solution that can reduce the resistance of main reinforcement and sonic logging pipe installation, enabling fast and efficient installation operations; A support system that can be flexibly adjusted according to the parameters of the steel cage and site conditions, improving construction adaptability; A simple, low-cost, and easy-to-implement steel cage fabrication solution. Summary of the Invention

[0007] This invention proposes a low-friction support and threading coordination method in the processing of rebar cages. Through a "steady-rolling" dual-mode node layout and a controllable friction interface, it enables low-resistance rotation of the rebar cage under manual drive and long-distance single-point threading.

[0008] To achieve the above objectives, the present invention is implemented as follows: A method for low-friction support and threading coordination in the fabrication of rebar cages, including... a) Dynamic layout: Based on the mass distribution and flexibility of the steel cage, several collinear support nodes are arranged along the axial direction. The node spacing can be infinitely adjusted within the range of 1 / 10 to 1 / 5 of the cage length and 2 m. b) Dual-state switching: A low-friction interface is set at the top of the node, the inner diameter of the sleeve is 2-4 mm larger than the support steel bar, and the rotational resistance torque is ≤0.01 kN·m; when positioning is required, it switches to the locked state; c) Drag-reducing penetration: Apply lubricating medium while rolling, friction coefficient ≤0.08, penetration speed increased ≥3 times; d) Non-powered construction: No motor or hydraulic system is required throughout the entire process, and ≤3 people can complete the processing of the steel cage.

[0009] Furthermore, the present invention also proposes a working system for the low-friction support and threading coordination method in the above-mentioned rebar cage processing; comprising: Support node module: triangular bracket + rotatable pulley sleeve, which can switch between rolling / locking states under external force; Spacing adjustment connecting rod: telescopic type, used to quickly change the node span; Shared base: fixed by on-site anchors or counterweights.

[0010] This invention employs the aforementioned design, where a pulley sleeve at the top of the support node transforms the sliding between the reinforcing cage and the support into rolling, reducing the starting torque for rotation to below 0.02 kN·m, allowing for easy manual rotation of the cage. When positioning is required, a wedge block or cotter pin is inserted between the sleeve and the triangular support, immediately causing the node to lose its rotational freedom and form a stable fulcrum. During welding, the cage's sway does not exceed two millimeters. After multiple nodes maintain collinearity along the axis, the reinforcing cage's self-weight deflection is evenly distributed among the continuous fulcrums. Even with a slenderness ratio greater than 25, the main reinforcement can still be pushed at a single point without mid-way jamming. The node spacing can be steplessly adjusted within the range of 1 / 10 to 1 / 5 of the cage length, ensuring that the maximum bending moment always falls near the fulcrum and preventing plastic deformation. The rolling section and locking section are arranged alternately according to the process. The locking section provides a rigid workbench, while the rolling section continuously supplies the main reinforcement and sonic logging pipes. Welding and installation no longer wait for each other, and the overall cycle time is shortened by more than one-third. The entire system does not require external power, reduces the on-site footprint by about half, and allows two steel cages to be processed in parallel on the same work surface, doubling the daily production capacity. All components are made of on-site steel bars and standard sleeves, which can be reused and meet the requirements of green construction. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the overall low-friction support and penetration coordination system shown in this invention.

[0012] Figure 2 This is a schematic diagram showing the positions of the support node and the reinforcing cage as illustrated in this invention.

[0013] Figure 3 This is a schematic diagram of the structure of the rolling node shown in this invention.

[0014] Figure 4 This is a schematic diagram of the structure of the fixed node shown in this invention. Detailed Implementation

[0015] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with the accompanying drawings and preferred embodiments, is provided below.

[0016] Example 1 The following combination Figures 1-4 Taking a Φ32 main reinforcement and a 20m long bored pile reinforcement cage as an example, the specific construction steps are explained.

[0017] Node creation 1.1 Scrolling nodes, such as Figure 3 Take two Φ25 threaded steel bars, bend them into an equilateral triangle support with a side length of 0.4m, and weld the two triangles together with Φ20 steel bars to form a whole with a length of 1m. First, insert a Φ32×60mm ordinary connecting sleeve (5mm wall thickness) into the top horizontal rib, and then weld it to the triangular brackets on both sides. The inner diameter of the sleeve is 3mm larger than the outer diameter of the horizontal rib, and it can rotate freely to form a pulley. An 8mm through hole is reserved at one end of the sleeve for a spare R-type cotter pin, used for locking.

[0018] 1.2 Fixed / locked nodes, such as Figure 4 Similarly, Φ25 steel bars are welded into 0.4m equilateral triangles with a spacing of 2m, and Φ16 threaded steel bars are used in the middle to connect them in a "bench-like" manner; A 30mm deep limiting groove is bent out at the center of the top horizontal rib. The groove width is 2mm larger than the diameter of the main rib, and the gap on one side is ≤3mm to ensure that it does not shake when locked.

[0019] On-site setup, such as Figure 1 Lay out lines on the hardened ground at 2m intervals, first place the fixed nodes, then place the rolling nodes alternately, and use a string to ensure that the top surfaces of all nodes are collinear and the height difference is ≤2mm; The node base is secured with M16 expansion bolts or sandbags on site to prevent slippage during pushing.

[0020] The steel cage is in place, such as Figure 2 Use a crane or manual labor to lift the semi-finished cage onto the node, so that the main reinforcement falls into the rolling node sleeve and the fixed node limiting groove; at this time, the nodes are all in a rolling state, and the cage can be turned by one hand.

[0021] Stirrup welding operation Insert the rolling node sleeve of the corresponding welding section into the cotter pin (or wed in the wooden block), switch to the locked state, and form a rigid worktable; Workers weld around the cage, and after welding 1-2 stirrups, they pull out the cotter pins, restore the rolling state, and push the cage to the next welding surface, repeating the locking-welding-releasing cycle.

[0022] Installation of main reinforcement and sonic logging pipe Keep all nodes in a rolling state and apply water-based release agent to the sleeve surface as a lubricating medium; The Φ32 main rib or Φ50 sonic logging tube is pushed in from one end, and the pulley is used for rolling guidance. The actual measured thrust is ≤18N, and a single person can complete the installation of a 20m long line. During installation, the cage should be rotated continuously to prevent the reinforcing bars from colliding with the stirrups.

[0023] Node spacing adjustment If the cage diameter or weight changes, loosen the connecting sleeve bolts between the nodes and slide them along the long hole in the base. The adjustment can be made steplessly within the range of 1.5 to 2.5m. After adjustment, tighten them again.

[0024] Demolition and Relocation After processing is completed, the locking pin is pulled out, the steel cage is removed, the node module remains in place, and the next cage is directly hoisted down, achieving "zero assembly" turnover.

[0025] By adopting the above steps, the processing time of a 20m long steel cage is reduced from the traditional 2.5 hours to 30 minutes. No crane or thread rolling machine is needed on site, and 3 people can complete the entire operation. The joint materials can be 100% recycled, which meets the requirements of green construction.

[0026] In summary, this specific implementation method achieves low-resistance operation of rebar cage rotation and long-distance threading without the need for additional power on site through the combination of triangular brackets and pulley sleeves; by utilizing "rolling-locking" dual-state switching, welding positioning and material feeding are completed within the same support system, eliminating the need for traditional scaffolds or thread rolling machines; the node spacing can be steplessly adjusted to adapt to different cage diameters and site conditions; all components use on-site rebar and standard sleeves, allowing for rapid assembly and disassembly and repeated use, thereby significantly shortening the processing cycle, reducing mechanical dependence and site occupation.

[0027] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for low-friction support and installation coordination in the processing of steel cages, characterized in that, include: a) Based on the mass distribution and flexibility characteristics of the steel cage, several support nodes are dynamically arranged along its axial direction, and the top surfaces of each node are collinear. b) Configure the support node as a dual-state node that can switch between "scrolling state" and "locked state": – Rolling state: A rotatable low-friction interface is formed at the top of the node, the driving resistance of the steel cage rotating around its own axis is ≤0.02 kN·m, and axial slippage is allowed; – Locked state: The top of the node forms rigid contact with the reinforcing cage, restricting its rotation and axial slippage; c) In the rolling state, the axial penetration resistance of the main rib or sonic logging tube is converted into rolling friction force by the low friction interface, so as to achieve long-distance single-point pushing with a thrust of ≤20 N. d) During the welding / tying process, switch the corresponding node to the locked state to maintain the spatial shape error of the rebar cage ≤5mm; e) No external power is required throughout the process, and the processing can be completed by ≤3 people.

2. The low-friction support and threading coordination method in the steel cage processing according to claim 1, characterized in that: The low-friction interface is composed of a triangular steel bar support and a pulley sleeve freely fitted on it. The inner diameter of the sleeve is 2 to 4 mm larger than the outer diameter of the steel bar support, and the rotational resistance torque of the sleeve is ≤0.01 kN·m.

3. The low-friction support and threading coordination method in the steel cage processing according to claim 1 or 2, characterized in that: Each support node alternates between rolling and locked states, with the node spacing being 1 / 10 to 1 / 5 of the length of the steel cage, and steplessly adjustable within a 2-meter range.

4. The low-friction support and threading coordination method in the steel cage processing according to claim 1, characterized in that: The locking state is achieved through a "bench-style" steel welded frame, with a top limiting groove depth of 30-50 mm and a single-sided gap of ≤3 mm.

5. The low-friction support and threading coordination method in the steel cage processing according to claim 1, characterized in that: Before installation, apply a lubricating medium to the low-friction interface to ensure that the coefficient of friction is ≤0.

08.

6. The low-friction support and threading coordination method in the steel cage processing according to claim 1, characterized in that: The entire support system has no motor or hydraulic system and is manually operated.

7. A low-friction support and threading coordination system for implementing the low-friction support and threading coordination method in the processing of steel cages according to any one of claims 1-6, comprising: The support node module has a triangular bracket and a rotatable pulley sleeve, and can switch between rolling and locked states; The node spacing adjustment connecting rod is extendable in length. The shared base allows for quick on-site installation using anchors or counterweights.

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