Integrated forming production line for prefabricated small box girder steel bar component

Abstract

The invention provides a prefabricated small box girder steel bar component integrated forming production line which comprises a longitudinal bar inserting mechanism, the longitudinal bar inserting mechanism is arranged on a bottom rail, a positioning mechanism is arranged on one side of the longitudinal bar inserting mechanism, a plurality of steel bar sheet bodies are located in the positioning mechanism, and a plurality of reinforcing longitudinal bars are arranged in the longitudinal bar inserting mechanism; a longitudinal bar discharging mechanism is further arranged on the bottom rail and connected with the longitudinal bar inserting mechanism through a feeding mechanism. Integrated operation is achieved, semi-finished products do not need to be manually transferred, the production process is simplified, the production efficiency is greatly improved, the large-scale and standardized production requirements are met, meanwhile, accurate positioning of reinforcing steel bar sheet bodies is achieved through abutting grooves of the positioning mechanisms, longitudinal bars are guided and supported in all directions through V-shaped traction rollers of the connecting and guiding assemblies, and the production efficiency is improved. The traction assembly and the driving assembly are matched to achieve synchronous and stable insertion of the longitudinal bars, deviation and dislocation of the longitudinal bars and the steel bar sheet bodies are effectively avoided, and the forming precision and the overall strength of the steel bar framework are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of precast component processing technology for bridge engineering, and in particular to an integrated production line for precast small box girder steel reinforcement components. Background Technology

[0002] As a core load-bearing component in bridge engineering, the processing precision and forming efficiency of the steel reinforcement of precast small box girders directly affect the overall safety and construction progress of the bridge structure.

[0003] Currently, the processing of precast small box girder steel reinforcement components mostly adopts a decentralized operation mode, that is, the longitudinal reinforcement cutting and straightening, steel reinforcement sheet processing, longitudinal reinforcement and sheet interlacing, binding and welding and other processes are completed by different equipment and manual labor.

[0004] The above-mentioned operation mode has the following problems: First, the insertion and positioning of longitudinal bars and steel sheet bodies rely on manual operation, which is not only labor-intensive, but also has a large positioning error, and is prone to problems such as longitudinal bar displacement and sheet body misalignment. Repeated adjustments are required afterward, resulting in low efficiency.

[0005] Secondly, the production line layout lacks a systematic approach, the various processes are poorly connected, and integrated operations are not achieved, resulting in long production cycles and difficulty in meeting the large-scale construction needs of bridge projects.

[0006] Therefore, an integrated production line for prefabricated small box girder steel reinforcement components is proposed to solve the above problems. Summary of the Invention

[0007] To address the problems mentioned in the background section, this invention provides an integrated molding production line for prefabricated small box girder steel reinforcement components, which improves processing accuracy and production efficiency while reducing labor intensity.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is: an integrated forming production line for prefabricated small box girder steel reinforcement components, including a longitudinal reinforcement insertion mechanism, which is located on the bottom track, a positioning mechanism is provided on one side of the longitudinal reinforcement insertion mechanism, multiple steel reinforcement pieces are located inside the positioning mechanism, and multiple reinforcing longitudinal ribs are provided inside the longitudinal reinforcement insertion mechanism. The bottom track is also equipped with a longitudinal rib feeding mechanism, which is connected to the longitudinal rib insertion mechanism through the feeding mechanism.

[0009] Preferably, the positioning mechanism includes a fixed frame located on the outside of the bottom track, a movable frame movably connected to the bottom track inside the fixed frame, four abutment rods fixed on the inside of the movable frame, and multiple evenly distributed abutment grooves on the outside of the abutment rods, with the steel bar sheet abutting against the inside of the abutment groove.

[0010] Preferably, the longitudinal rib insertion mechanism includes a drive plate, which is located on the right side of the fixed frame, and the drive plate is provided with multiple sets of longitudinal rib drive components inside; The internal structure of the fixing frame is equipped with multiple sets of guide components for supporting the longitudinal reinforcement; The right side of the fixing frame is equipped with a traction component for traction of the longitudinal reinforcement.

[0011] Preferably, the drive hole in the longitudinal rib drive assembly is opened on the drive plate, and a support roller corresponding to the drive hole is fixed on the right side of the drive plate. A fixing plate is fixed on the right side of the drive plate, and a first cylinder is fixed on the top of the fixing plate, extending to its bottom. The output end of the first cylinder is rotatably connected to a drive roller via a roller frame. A drive motor connected to the drive roller is fixed on the outside of the roller frame.

[0012] Preferably, the receiving assembly includes a lower receiving portion, an upper receiving portion, and a side receiving portion; The bottom support in the lower connecting part is fixed on the outside of the two lower abutment rods. Multiple lower support plates are fixed inside the bottom support. Four lower traction rollers are rotatably connected to the opposite side of each adjacent lower support plate. The two horizontally corresponding lower traction rollers are distributed in a V-shape. The top support in the upper connecting part is fixed on the outside of the two upper abutment rods. Multiple upper support plates are fixed at the bottom of the top support. Four lower traction rollers are rotatably connected to the opposite side of the adjacent upper support plates. The two horizontally corresponding lower traction rollers are distributed in a V-shape. The two diagonal rods in the side connection section are fixed between the outer sides of the two abutment rods on the same side. The opposite sides of the two diagonal rods are rotatably connected to four side traction rollers through multiple crossbars, and the adjacent two side traction rollers are distributed in a V-shape.

[0013] Preferably, the traction plate in the traction assembly is movably connected to the top of the bottom track via the second drive component and is located on the left side of the fixed frame. The traction plate has multiple traction holes corresponding to the drive holes. Two mounting plates are fixed on the left side of the traction plate, located on both sides of the traction hole. A second cylinder extending to the opposite side of each mounting plate is fixed on the opposite side of the two mounting plates. A clamping block is fixed on the piston rod of each of the two second cylinders.

[0014] Preferably, the disc straightener in the longitudinal rib feeding mechanism is located on one side of the bottom track, and a longitudinal rib preparation platform is provided on one side of the output end of the disc straightener.

[0015] Preferably, the bottom track has a support mechanism located below the traction assembly; The mounting frame in the support mechanism is fixed inside the bottom track, and a base plate is fixed on the top of the mounting frame. The top of the base plate is arc-shaped, and the highest point corresponds to the bottom position of the steel bar sheet.

[0016] Preferably, a binding and welding mechanism is provided between the traction plate and the fixing frame; The bundling and welding mechanism includes a bundling section and a welding section. The bundling bracket in the bundling section is fixed to the top of the bottom track and located on the outside of the moving frame. Multiple bundling robotic arms are provided on the inside of the bundling bracket. The welding bracket in the welding section is fixed to the top of the bottom track and located outside the moving frame. Multiple welding robotic arms are fixed to one side of the welding bracket.

[0017] Preferably, a jig and a crane are provided on one side of the bottom track. The jig is used to place the formed steel bar sheets and reinforcing longitudinal bars, and the crane is used to lift the steel bar sheets and the formed steel bar sheets and reinforcing longitudinal bars.

[0018] This invention provides an integrated molding production line for precast small box girder steel reinforcement components, with the following advantages: 1. This invention achieves integrated operation, combining multiple processes such as longitudinal bar cutting, straightening, insertion, bar sheet positioning, assembly, and bundling welding. It eliminates the need for manual transfer of semi-finished products, simplifies the production process, significantly improves production efficiency, and adapts to the needs of large-scale and standardized production.

[0019] 2. This invention achieves precise positioning of the reinforcing bar sheet through the abutment groove of the positioning mechanism, and the V-shaped traction roller of the receiving component provides all-round guidance and support for the longitudinal reinforcement. The traction component and the drive component work together to achieve synchronous and smooth insertion of the longitudinal reinforcement, effectively avoiding the offset and misalignment of the longitudinal reinforcement and the reinforcing bar sheet, and ensuring the forming accuracy and overall strength of the reinforcing bar skeleton.

[0020] 3. In this invention, the processes of cutting, inserting, binding, and welding of longitudinal ribs are all automated, reducing manual intervention, lowering the intensity of manual labor, avoiding errors caused by manual operation, and improving the stability of processing quality. Attached Figure Description

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments: Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a three-dimensional structural diagram of the bottom track and the structure above it in this invention; Figure 3 This is a three-dimensional structural diagram of the support mechanism and the binding and welding mechanism in this invention; Figure 4 This is a three-dimensional structural diagram of the bottom track and positioning mechanism in this invention; Figure 5 This is a three-dimensional structural diagram of the abutment rod and the reinforcing steel sheet in this invention; Figure 6 This is a right view of the steel reinforcement sheet and the reinforcing longitudinal bars in this invention; Figure 7This is a front view of the steel bar sheet, reinforcing longitudinal bars, drive plate, and traction assembly in this invention; Figure 8 This is a right view of the drive plate and longitudinal rib drive assembly in this invention; Figure 9 For the present invention Figure 8 Enlarged view of A in the middle; Figure 10 This is a three-dimensional structural diagram of the bottom track, positioning mechanism, and receiving assembly in this invention; Figure 11 This is a left view of the bottom track, traction assembly, and support mechanism in this invention; Figure 12 For the present invention Figure 11 Enlarged view of B in the middle; Figure 13 This is a cross-sectional view of the bottom track, support mechanism, and steel reinforcement sheet in this invention; Figure 14 This is a right view of the jig, crane, and steel reinforcement cage in this invention.

[0022] In the diagram: 1. Longitudinal rib insertion mechanism; 11. Drive plate; 12. Longitudinal rib drive assembly; 121. Drive hole; 122. Support roller; 123. Fixing plate; 124. First cylinder; 125. Roller frame; 126. Drive roller; 127. Drive motor; 13. Receiving assembly; 131. Bottom support; 132. Lower traction roller; 133. Top support; 134. Upper traction roller; 135. Diagonal bar; 136. Crossbar; 137. Side traction roller; 14. Traction assembly; 141. Traction plate; 142. Traction hole; 143. 1. Mounting plate; 144. Second cylinder; 145. Clamping block; 2. Bottom track; 3. Positioning mechanism; 31. Fixed frame; 32. Moving frame; 33. Abutting rod; 34. Abutting groove; 4. Rebar sheet; 5. Reinforcing longitudinal bar; 6. Longitudinal bar cutting mechanism; 61. Disc straightening machine; 62. Longitudinal bar preparation platform; 7. Support mechanism; 71. Mounting frame; 72. Base plate; 8. Bundling and welding mechanism; 81. Bundling bracket; 82. Bundling robotic arm; 83. Welding bracket; 84. Welding robotic arm; 9. Jig; 10. Crane. Detailed Implementation

[0023] like Figure 1-12 As shown, the precast small box girder steel reinforcement component integrated molding production line includes a longitudinal reinforcement insertion mechanism 1, which is located on the bottom track 2 and can move horizontally along the bottom track 2 to achieve precise insertion of longitudinal reinforcement.

[0024] A positioning mechanism 3 is provided on one side of the longitudinal reinforcement insertion mechanism 1. Multiple steel bar pieces 4 are located inside the positioning mechanism 3. The positioning mechanism 3 is used to limit the steel bar pieces 4, ensure the spacing and verticality of the steel bar pieces 4, and provide a positioning reference for longitudinal reinforcement insertion.

[0025] The longitudinal reinforcement insertion mechanism 1 has multiple reinforcing longitudinal ribs 5 inside. The reinforcing longitudinal ribs 5 interweave with the steel bar sheet 4 to form the main structure of the steel bar skeleton.

[0026] The bottom track 2 is also equipped with a longitudinal rib cutting mechanism 6. The longitudinal rib cutting mechanism 6 is connected to the longitudinal rib insertion mechanism 1 through the feeding mechanism. It is used to straighten and cut the disc-shaped longitudinal ribs. After cutting them to the preset length, they are transported to the longitudinal rib insertion mechanism 1 through the feeding mechanism, so as to realize the automated cutting and feeding of longitudinal ribs and reduce manual intervention.

[0027] like Figure 4-5 As shown, in the preferred embodiment, the positioning mechanism 3 is used to accurately position the steel bar sheet 4 to ensure the assembly accuracy of the steel bar sheet 4. Its structure includes a fixed frame 31, a movable frame 32, abutting rod 33, and abutting groove 34.

[0028] The fixed frame 31 is fixed to the outside of the bottom track 2 to provide protection for the entire positioning mechanism. The movable frame 32 is located inside the fixed frame 31 and is movably connected to the bottom track 2. The movable frame 32 can be driven by the first driving component to move left and right along the bottom track 2. Four abutment rods 33 are fixedly installed on the inner side of the movable frame 32. The four abutment rods 33 correspond to four points on the outside of the steel bar sheet 4. Multiple evenly distributed abutment grooves 34 are opened on the outer side of the abutment rods 33. The width of the abutment grooves 34 is adapted to the diameter of the steel bar sheet 4. The steel bar sheet 4 abuts against the inside of the abutment grooves 34 to achieve neat arrangement and precise positioning of multiple steel bar sheets 4 and avoid displacement during assembly.

[0029] In a preferred embodiment, the first driving component includes a housing located at the bottom of the movable frame 32. Inside the housing is a dual-head servo geared motor. The output shaft of the dual-head servo geared motor is connected to a rotating shaft extending to the outside of the housing. Both ends of the rotating shaft are connected to rollers, which rest against the inside of the movable frame 32.

[0030] When the dual-head servo geared motor is started, the two output shafts of the dual-head servo geared motor will drive the two rollers to roll, thereby driving the moving frame 32 to move in translation. The moving frame 32 can drive the steel bar sheet 4 inside it to move in translation through the abutment rod 33 and the abutment groove 34.

[0031] like Figure 8-12 As shown, in the preferred embodiment, the longitudinal rib insertion mechanism 1 includes a drive plate 11, which is located on the right side of the fixed frame 31. The drive plate 11 is fixedly connected to the bottom track 2. The drive plate 11 is provided with multiple sets of longitudinal rib drive assemblies 12 inside. The longitudinal rib drive assemblies 12 are used to drive the reinforcing longitudinal ribs 5 to move axially to achieve automated insertion.

[0032] The fixing frame 31 is equipped with multiple sets of guide components 13 inside, which are used to support and guide the reinforcing longitudinal rib 5, so as to prevent the reinforcing longitudinal rib 5 from bending and deforming during the insertion process and to ensure the straightness of the reinforcing longitudinal rib 5 during insertion.

[0033] The right side of the fixing frame 31 is provided with a traction component 14, which is used to fix and pull the other end of the reinforcing longitudinal rib 5, so that the reinforcing longitudinal rib 5 can perform translational movement.

[0034] like Figure 8-9 As shown, in the preferred embodiment, the drive holes 121 in the longitudinal rib drive assembly 12 are opened on the drive plate 11, and the number of drive holes 121 is the same as the number of reinforcing longitudinal ribs 5, for passing through the reinforcing longitudinal ribs 5.

[0035] A support roller 122 corresponding to the drive hole 121 is fixed on the right side of the drive plate 11. The support roller 122 is used to support the reinforcing longitudinal rib 5 and reduce the friction when the longitudinal rib moves.

[0036] A fixing plate 123 is fixed on the right side of the drive plate 11. A first cylinder 124 is fixed on the top of the fixing plate 123, penetrating its bottom. The output end of the first cylinder 124 is rotatably connected to a drive roller 126 via a roller frame 125. A drive motor 127 connected to the drive roller 126 is fixed on the outside of the roller frame 125.

[0037] The first cylinder 124 pushes the drive roller 126 downward to cooperate with the support roller 122 to clamp the reinforcing longitudinal rib 5. Then, the drive motor 127 drives the drive roller 126 to rotate, which drives the reinforcing longitudinal rib 5 to move axially, realizing the automatic insertion of the longitudinal rib.

[0038] like Figure 1 As shown, in the preferred embodiment, the feeding mechanism includes a vision recognition mechanism and an insertion robot. The vision recognition mechanism identifies the position of the drive hole 121, and the insertion robot clamps the reinforcing rib 5 and inserts it into the corresponding drive hole 121. Then, the support roller 122 and the drive roller 126 clamp the inserted reinforcing rib 5 and drive it to move in bearing mode. With the help of multiple sets of receiving components 13, the insertion of the reinforcing rib 5 is completed.

[0039] like Figure 10 As shown, in the preferred embodiment, the guide assembly 13 includes a lower guide part, an upper guide part, and a side guide part. The three work together to provide all-round support and guidance for the longitudinal reinforcement from the bottom, top, and sides, ensuring that the longitudinal reinforcement maintains straightness throughout the insertion process.

[0040] The lower connecting part consists of a bottom support 131 and a lower traction roller 132. The bottom support 131 is fixed on the outside of the two lower abutment rods 33. Multiple lower support plates are fixed inside the bottom support 131. Four lower traction rollers 132 are rotatably connected to the opposite side of each adjacent lower support plate. The two horizontally corresponding lower traction rollers 132 are distributed in a V-shape to support the bottom of the reinforcing longitudinal rib 5. The V-shaped structure can limit the longitudinal rib and prevent it from shifting to the left or right. At the same time, the rotation of the traction roller can reduce the friction when the reinforcing longitudinal rib 5 moves.

[0041] It should be noted that the four lower traction rollers 132 are divided into upper and lower groups. The two groups of lower traction rollers 132 can provide support for the two lower reinforcing longitudinal ribs 5, one above the other.

[0042] like Figure 10 As shown, in the preferred embodiment, the upper connecting part consists of a top support 133 and an upper traction roller 134. The top support 133 is fixed to the outside of the two upper abutment rods 33. Multiple upper support plates are fixed to the bottom of the top support 133. Multiple upper traction rollers 134 are rotatably connected to the opposite side of adjacent upper support plates. The two horizontally corresponding upper traction rollers 134 are distributed in a V-shape to support the top of the reinforcing longitudinal rib 5. The V-shaped structure can limit the longitudinal rib and prevent it from shifting to the left or right. At the same time, the rotation of the traction roller can reduce the friction when the reinforcing longitudinal rib 5 moves.

[0043] It should be noted that the four upper traction rollers 134 are divided into upper and lower groups, and the two lower traction rollers 132 can provide support for the two upper reinforcing longitudinal ribs 5, one above the other.

[0044] like Figure 10 As shown, in the preferred embodiment, the side connecting part consists of a diagonal bar 135, a horizontal bar 136, and a side traction roller 137. The two diagonal bars 135 are respectively fixed between the outer sides of the two abutment bars 33 on the same side. On the opposite side of the two diagonal bars 135, four side traction rollers 137 are rotatably connected through multiple horizontal bars 136. Two adjacent side traction rollers 137 are distributed in a V-shape to support the side of the reinforcing longitudinal rib 5. The V-shaped distribution of the traction rollers can limit the reinforcing longitudinal rib 5 in all directions to ensure that the reinforcing longitudinal rib 5 always maintains a straight state during the insertion process. At the same time, the traction rollers can rotate synchronously with the movement of the reinforcing longitudinal rib 5 to reduce friction.

[0045] It should be noted that the four side traction rollers 137 are divided into two groups, left and right. The two groups of side traction rollers 137 can support the two side reinforcing longitudinal ribs 5 on the left and right respectively.

[0046] like Figure 11-12 As shown, in the preferred embodiment, the traction assembly 14 is located on the left side of the fixing frame 31 and is used to traction the reinforcing longitudinal rib 5. It includes a traction plate 141, a traction hole 142, a mounting plate 143, a second cylinder 144, and a clamping block 145.

[0047] The traction plate 141 is movably connected to the top of the bottom track 2 via the second drive component and can move along the bottom track 2. The traction plate 141 has multiple traction holes 142, which correspond one-to-one with the drive holes 121. After the end of the reinforcing longitudinal rib 5 passes through multiple steel bar sheets 4, it will continue to pass through the traction holes 142.

[0048] Two mounting plates 143 are provided, which are fixed on the left side of the traction plate 141 and located on both sides of the traction hole 142. The second cylinder 144 is horizontally fixed on the opposite side of the mounting plate 143. Its output end passes through the mounting plate 143 and is connected to the clamping block 145. The inner side of the clamping block 145 is provided with anti-slip texture for clamping the reinforcing longitudinal rib 5.

[0049] During operation, after the end of the reinforcing longitudinal rib 5 passes through the traction hole 142, it indicates that the reinforcing longitudinal rib 5 has passed through all the steel bar sheets 4. At this time, the drive motor 127 is turned off, and the first cylinder 124 is started in reverse, so that the longitudinal rib drive assembly 12 loses its clamping and driving of the reinforcing longitudinal rib 5. Then, the two second cylinders 144 are started, and the second cylinders 144 drive the two clamping blocks 145 to move relative to each other, clamping the end of the reinforcing longitudinal rib 5. Subsequently, the traction plate 141 moves to the left along the bottom track 2, which can drive the reinforcing longitudinal rib 5 to move to the left.

[0050] It should be noted that when the traction plate 141 drives the reinforcing longitudinal bar 5 to move to the left, the second driving component simultaneously drives the moving frame 32 to move to the left. The moving frame 32 can drive the steel bar sheet 4 inside it to move in translation through the abutment rod 33 and the abutment groove 34.

[0051] The second drive component has the same structure as the first drive component, and the two dual-head servo geared motors are of the same model. They are driven synchronously so that the steel bar sheet 4 and the reinforcing longitudinal bar 5 move synchronously to the left.

[0052] like Figure 2-3 As shown, in the preferred embodiment, the binding and welding mechanism 8 is located between the traction plate 141 and the fixing frame 31. It is used to automatically bind and weld the reinforcing longitudinal bars 5 and the steel bar sheets 4 after they are assembled to form a steel bar skeleton. At the same time, it also realizes the integrated forming of the steel bar skeleton and improves the connection strength.

[0053] The binding and welding mechanism 8 includes a binding part and a welding part. The binding part includes a binding bracket 81 and a binding robotic arm 82. The binding bracket 81 is fixed on the top of the bottom track 2 and located on the outside of the moving frame 32. Multiple binding robotic arms 82 are provided and evenly distributed on the inside of the binding bracket 81 for automatically binding the connection between the longitudinal reinforcement and the steel bar sheet 4.

[0054] The welding section includes a welding bracket 83 and a welding robotic arm 84. The welding bracket 83 is fixed on the top of the bottom track 2 and is also located on the outside of the moving frame 32, adjacent to the binding bracket 81. Multiple welding robotic arms 84 are provided and fixed on one side of the welding bracket 83. They are used to automatically weld the connection between the longitudinal reinforcement and the steel bar sheet 4 to ensure a firm connection.

[0055] When the reinforcing longitudinal bar 5 and the steel bar sheet 4 move to the left at the same time, they will pass through the binding bracket 81 and the welding bracket 83 in sequence. The binding robotic arm 82 and the welding robotic arm 84 can perform binding and welding operations on the reinforcing longitudinal bar 5 and the steel bar sheet 4, so that...

[0056] like Figure 13 As shown, in the preferred embodiment, the support mechanism 7 is located inside the bottom track 2, below the traction component 14, and is used to provide bottom support for the steel reinforcement skeleton during the assembly process to prevent the steel reinforcement skeleton from deforming due to its own weight.

[0057] The support mechanism 7 includes a mounting frame 71 and a base plate 72. The mounting frame 71 is fixed inside the bottom track 2 to provide support for the entire steel reinforcement cage. The base plate 72 is fixed on the top of the mounting frame 71. The top of the base plate 72 is arc-shaped, and its highest point corresponds to the bottom position of the steel reinforcement sheet 4, which can fit the bottom contour of the steel reinforcement cage and achieve stable support for the steel reinforcement cage.

[0058] During the process of moving, binding, and welding the reinforcing longitudinal bars 5 and the steel sheet 4, the part that has formed the steel skeleton will be supported at the bottom by the base plate 72 to prevent the steel skeleton from deforming.

[0059] like Figure 1 As shown, in the preferred embodiment, the longitudinal rib feeding mechanism 6 is used to realize the automatic feeding and straightening of the reinforcing longitudinal rib 5, and to provide qualified longitudinal rib raw materials for the longitudinal rib insertion mechanism 1. It includes a disc straightening machine 61 and a longitudinal rib preparation platform 62.

[0060] The disc straightener 61 is located on one side of the bottom track 2 and is used to straighten the disc-shaped longitudinal rib material, remove the bending deformation of the longitudinal rib, and ensure the straightness of the longitudinal rib. The longitudinal rib preparation platform 62 is located on one side of the output end of the disc straightener 61 and is used to temporarily store the straightened longitudinal rib. The feeding mechanism transports the longitudinal rib on the longitudinal rib preparation platform 62 to the drive hole 121 of the longitudinal rib insertion mechanism 1 to realize automatic feeding.

[0061] In the preferred embodiment, the processing mechanism for the steel bar sheet 4 includes another sheet straightening machine 61, a steel bar bending machine, a magnetic lifting device, a positioning platform, a feeding robot, and a welding robot.

[0062] The disc straightener 61 is located on the left side of the rebar bending machine, the positioning platform is located on the rear side of the rebar bending machine, the magnetic lifting device is installed across the top of the rebar bending machine and the positioning platform, and the feeding robot and welding robot are both installed on the positioning platform.

[0063] After being straightened and sheared at high speed by the coil straightener 61, the coiled steel bars are formed into ordinary steel bars and then enter the steel bar bending machine. The steel bar bending machine bends the ordinary steel bars into steel bar sheets 4. The steel bar sheets 4 are placed into the positioning platform by a magnetic suction hanger. The steel bar sheets 4 are fixed and clamped by a multi-servo cylinder in the positioning platform. The loading robot automatically grabs and installs the guide angle steel bars and hook bars. The welding robot locates the weld position by scanning the component with a line laser and then welds it.

[0064] like Figure 14 As shown, in the preferred embodiment, a jig 9 and a crane 10 are provided on one side of the bottom track 2. The jig 9 is used to place the formed steel bar sheet 4 and the reinforcing longitudinal bar 5, and the crane 10 is used to lift the formed steel bar skeleton.

[0065] The jig 9 is used to place the steel reinforcement skeleton, while the crane 10 can not only lift the steel reinforcement sheet 4 into the interior of the movable frame 32, but also lift the already formed steel reinforcement skeleton and place it into the jig 9.

[0066] A gripping robotic arm is also provided between the positioning platform and the positioning mechanism 3. After the steel bar sheet 4 is welded on the positioning platform, the positioning platform releases the positioning of the steel bar sheet 4. At this time, the gripping robotic arm grips the steel bar sheet 4 and flips it so that it can be placed vertically into the positioning mechanism 3.

[0067] In the preferred embodiment, the dual-head servo geared motor is model SEW DRS200M4 / 2N, with a reduction ratio of 20:1 and a power of 2.2kW.

[0068] Both cylinder 124 and cylinder 144 are Airtac TN25×30 twin-shaft cylinders, with a cylinder diameter of 25mm, a stroke of 30mm, a rated thrust of 800N, and a working air pressure of 0.4-0.8MPa.

[0069] The drive motor, model 127, is a Panasonic MSMD042G1U, with a rated power of 400W, a rated speed of 3000r / min, and a torque of 1.27N. m, compatible with Panasonic MBDKT2510E drive. This model has high speed regulation accuracy and can achieve low-speed high torque output, avoiding bending due to uneven speed when the reinforcing longitudinal ribs 5 are inserted. The 400W power is adapted to the load requirements of drive roller 126 and meets the requirements of continuous operation.

[0070] The visual recognition mechanism in the feeding system uses a Hikvision MV-CE013-50GM area array industrial camera and an MV-VC2100 vision controller. The Hikvision MV-CE013-50GM area array industrial camera uses a global shutter CCD sensor, with 1.3 million pixels and no ghosting, and a positioning accuracy of ±0.1mm. The MV-VC2100 vision controller has high efficiency and can quickly process images and accurately identify the coordinates of the drive holes. The two work together to provide a stable positioning reference for the robot arm in the production line, which is suitable for industrial scenarios with reinforced longitudinal ribs and automated feeding, ensuring feeding accuracy and continuity.

[0071] The insertion robot uses an Estun ER20-1780 6-axis articulated robot with a load capacity of 20kg and an arm span of 1780mm. First, its arm span is sufficient to cover the working area from the longitudinal rib preparation platform 62 to the longitudinal rib insertion mechanism 1. Second, its repeatability of ±0.05mm is sufficient to meet the requirement of accurately inserting the longitudinal rib insertion mechanism 1 into the drive hole 121.

[0072] Both the welding robot and the welding robotic arm 84 use FANUC Arc Mate 0iB, which is a dedicated arc welding robot with high integration, strong anti-interference, precise motion trajectory, and flexible welding posture.

[0073] The 82-type robotic arm for tying rebar includes a robotic arm and an automatic rebar tying machine. The robotic arm uses the Estun ER6-1600-S six-axis articulated robot with a rated load of 6kg, an arm span of 1600mm, and a repeatability of ±0.03mm. The automatic rebar tying machine uses the Jianke Machinery GZK40A automatic rebar tying machine, with a total weight controlled within 4.5kg. It has a compact shape, reducing the load and space occupation, and is installed at the output end of the robotic arm.

[0074] The disc straightener 61 adopts the Jianke GT12-40A CNC rebar straightening and cutting machine. Its multi-roller straightening system can effectively eliminate the bending stress of coiled rebar and achieve high straightness.

[0075] The B&R X20 series PLC is used as the main controller, which integrates motion control, logic control and robot collaboration functions, and can control various components.

[0076] Working principle: In this precast small box girder steel reinforcement component integrated molding production line, multiple steel reinforcement sheets 4 are first placed inside the moving frame 32 by the crane 10. The support groove 34 on the support rod 33 limits the position to ensure that the spacing and verticality of the steel reinforcement sheets 4 meet the design requirements. The feeding mechanism identifies the position of the drive hole 121 on the longitudinal reinforcement insertion mechanism 1, clamps the reinforcing longitudinal reinforcement 5 and inserts it into the corresponding drive hole 121. After the reinforcing longitudinal reinforcement 5 enters the drive hole 121, the first cylinder 124 is started. The first cylinder 124 pushes the drive roller 126 down to clamp the reinforcing longitudinal reinforcement 5 together with the support roller 122. Then the drive motor 127 is started. The drive motor 127 drives the drive roller 126 to rotate and drives the reinforcing longitudinal reinforcement 5 to pass out to the left along the axial direction. During the process of the longitudinal rib being passed through, it is guided by multiple sets of receiving components 13. The lower traction roller 132 supports the bottom reinforcing longitudinal rib 5, the upper traction roller 134 supports the top reinforcing longitudinal rib 5, and the side traction roller 137 supports the side reinforcing longitudinal rib 5 from both sides to ensure that the reinforcing longitudinal rib 5 maintains straight movement and prevents bending and deviation. After the front end of the longitudinal bar passes through all the steel bar sheets 4, it continues to pass into the traction hole 142 of the traction plate 141. At this time, the drive motor 127 is turned off and the first cylinder 124 is started in reverse, so that the longitudinal bar drive assembly 12 loses its clamping and driving of the reinforcing longitudinal bar 5. At the same time, the second cylinder 144 is started, and the second cylinder 144 drives the clamping block 145 to clamp the end of the longitudinal bar. Next, the traction plate 141 moves to the left along the track through the second drive component, while the moving frame 32 of the positioning mechanism 3 moves to the left synchronously through the first drive component, so that the steel bar sheet 4 and the reinforcing longitudinal bar 5 remain relatively stationary and move to the left as a whole. During the synchronous leftward movement of the steel bar sheet 4 and the reinforcing longitudinal bar 5, they first pass through the binding part of the binding and welding mechanism 8. The binding robotic arm 82 automatically binds the intersection of the reinforcing longitudinal bar 5 and the steel bar sheet 4. Then, they pass through the welding part, where the welding robotic arm 84 welds the key connection points to form a stable steel bar skeleton. After welding is completed, the traction component 14 is released and separated from the reinforcing longitudinal bar 5. At this time, the steel reinforcement cage can be sent into the jig 9 by the crane 10, and then each mechanism is reset to start the next operation.

[0077] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. An integrated production line for precast small box girder steel reinforcement components, characterized by: It includes a longitudinal reinforcement insertion mechanism (1), which is located on the bottom track (2). A positioning mechanism (3) is provided on one side of the longitudinal reinforcement insertion mechanism (1). Multiple steel bar sheets (4) are located inside the positioning mechanism (3). Multiple reinforcing longitudinal bars (5) are provided inside the longitudinal reinforcement insertion mechanism (1). The bottom track (2) is also equipped with a longitudinal rib feeding mechanism (6), which is connected to the longitudinal rib insertion mechanism (1) through the feeding mechanism.

2. The integrated molding production line for precast small box girder steel reinforcement components according to claim 1, characterized in that: The positioning mechanism (3) includes a fixed frame (31) located on the outside of the bottom track (2). Inside the fixed frame (31) is a movable frame (32) that is movably connected to the bottom track (2). Four abutting rods (33) are fixed on the inside of the movable frame (32). Multiple evenly distributed abutting grooves (34) are opened on the outside of the abutting rods (33). The steel bar sheet (4) abuts against the inside of the abutting groove (34).

3. The integrated molding production line for precast small box girder steel reinforcement components according to claim 2, characterized in that: The longitudinal rib insertion mechanism (1) includes a drive plate (11), which is located on the right side of the fixed frame (31). The drive plate (11) is provided with multiple sets of longitudinal rib drive components (12). The fixing frame (31) is equipped with multiple sets of connecting components (13) for supporting the longitudinal reinforcement; The right side of the fixing frame (31) is provided with a traction component (14) for traction of the longitudinal reinforcement.

4. The integrated molding production line for precast small box girder steel reinforcement components according to claim 3, characterized in that: The drive hole (121) in the longitudinal rib drive assembly (12) is opened on the drive plate (11), and the right side of the drive plate (11) is fixed with a support roller (122) corresponding to the drive hole (121). A fixing plate (123) is fixed on the right side of the drive plate (11). A first cylinder (124) is fixed on the top of the fixing plate (123) and extends to its bottom. The output end of the first cylinder (124) is rotatably connected to the drive roller (126) through the roller frame (125). A drive motor (127) connected to the drive roller (126) is fixed on the outside of the roller frame (125).

5. The integrated molding production line for precast small box girder steel reinforcement components according to claim 3, characterized in that: The connector assembly (13) includes a lower connector, an upper connector, and a side connector; The bottom support (131) in the lower connecting part is fixed on the outside of the two lower abutment rods (33). Multiple lower support plates are fixed inside the bottom support (131). Four lower traction rollers (132) are rotatably connected to the opposite side of the adjacent lower support plates. The two horizontally corresponding lower traction rollers (132) are distributed in a V shape. The top support (133) in the upper connecting part is fixed on the outside of the two upper abutment rods (33). Multiple upper support plates are fixed at the bottom of the top support (133). Four upper traction rollers (134) are rotatably connected to the opposite side of the adjacent upper support plates. The two horizontally corresponding upper traction rollers (134) are distributed in a V shape. Two diagonal rods (135) in the side connection section are fixed between the outer sides of two abutment rods (33) on the same side. The opposite sides of the two diagonal rods (135) are rotatably connected to four side traction rollers (137) through multiple crossbars (136). The two adjacent side traction rollers (137) are distributed in a V-shape.

6. The integrated molding production line for precast small box girder steel reinforcement components according to claim 4, characterized in that: The traction plate (141) in the traction assembly (14) is movably connected to the top of the bottom track (2) through the second drive component and is located on the left side of the fixing frame (31). The traction plate (141) has multiple traction holes (142) corresponding to the drive hole (121). Two mounting plates (143) are fixed on the left side of the traction plate (141), which are located on both sides of the traction hole (142). A second cylinder (144) extending to the opposite side of the two mounting plates (143) is fixed on each side. A clamping block (145) is fixed on the piston rod of each of the two second cylinders (144).

7. The integrated molding production line for precast small box girder steel reinforcement components according to claim 1, characterized in that: The disc straightener (61) in the longitudinal rib feeding mechanism (6) is located on one side of the bottom track (2), and the longitudinal rib preparation platform (62) is provided on one side of the output end of the disc straightener (61).

8. The integrated molding production line for precast small box girder steel reinforcement components according to claim 1, characterized in that: The bottom track (2) is equipped with a support mechanism (7) located below the traction assembly (14); The mounting frame (71) in the support mechanism (7) is fixed inside the bottom track (2). The top of the mounting frame (71) is fixed with a base plate (72). The top of the base plate (72) is arc-shaped, and the highest point corresponds to the bottom position of the steel strip (4).

9. The integrated molding production line for precast small box girder steel reinforcement components according to claim 2, characterized in that: A binding and welding mechanism (8) is provided between the traction plate (141) and the fixing frame (31); The bundling and welding mechanism (8) includes a bundling part and a welding part. The bundling bracket (81) in the bundling part is fixed to the top of the bottom track (2) and located on the outside of the moving frame (32). Multiple bundling robotic arms (82) are provided on the inside of the bundling bracket (81). The welding bracket (83) in the welding section is fixed on the top of the bottom track (2) and located on the outside of the moving frame (32). Multiple welding robotic arms (84) are fixed on one side of the welding bracket (83).

10. The integrated molding production line for precast small box girder steel reinforcement components according to claim 1, characterized in that: A jig (9) and a crane (10) are provided on one side of the bottom track (2). The jig (9) is used to place the formed steel bar sheet (4) and the reinforcing longitudinal bar (5). The crane (10) is used to lift the steel bar sheet (4) and the formed steel bar sheet (4) and the reinforcing longitudinal bar (5).

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