Anchorage cable factory integrated intelligent production line and control method
By integrating intelligent production lines and control methods, automated production of unbonded steel strands has been achieved, solving the problems of low efficiency and unstable quality in the production of geotechnical anchor cables. This has improved production efficiency and product quality, reduced labor costs, and enabled intelligent management.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- LIUZHOU OVM MASCH CO LTD
- Filing Date
- 2026-05-09
- Publication Date
- 2026-07-03
AI Technical Summary
The production efficiency of unbonded steel strands in the current production of geotechnical anchor cables is low, and there are problems such as excessive manual operation, unstable quality, and high risk of environmental pollution. Moreover, it is difficult to achieve automated production.
An integrated intelligent production line for anchor cable factories was designed, including a sliding platform, assembly operating table, cutting machine, oil injection device, clamping mechanism, etc. It integrates PE pipe automatic pipe cutting sub-line, steel strand oil injection sleeve production line, oil filling sub-line and steel strand chamfering sub-line, realizing the automated production of unbonded steel strand.
It has improved the production efficiency of geotechnical anchor cables, reduced labor costs, simplified the process, avoided environmental pollution, ensured product quality stability, and enabled intelligent product management and information traceability.
Smart Images
Figure CN122322893A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to automated production of anchor cables, and more specifically, to an integrated intelligent production line and control method for an anchor cable factory. Background Technology
[0002] like Figure 1 The diagram shows a structural schematic of a soil and rock anchor cable. The steel strands in the anchor cable include a tension section, a free section, and an anchorage section. The anchorage section is made of smooth steel strand; the free section is made of unbonded steel strand with a PE tube and grease inside; the tension section also has a PE layer, but during on-site construction, a portion of the PE layer needs to be removed before installing the anchor head for tensioning. Currently, unbonded steel strands (entirely coated with grease and PE) are used in the fabrication of soil and rock anchor cables. During cable fabrication, after the unbonded steel strands are cut to a fixed length, the PE layer of the anchorage section needs to be removed. To ensure complete removal of grease from the central wires of the steel strands and to avoid affecting subsequent anchorage stability, the steel strands need to be broken up, and the grease on each wire needs to be removed with a cleaning agent. After cleaning and drying, they are then twisted into a single strand. Finally, the anchor cable is assembled and packaged. However, when making steel strands for rock and soil anchor cables, the processes of breaking up, cleaning, drying and stranding the steel strands not only consume a lot of time and affect production efficiency, but also the grease that is washed out can easily cause environmental pollution. There is also the risk that the steel strands are not cleaned properly and that the strength of the steel strands after breaking up and re-stranding is weaker than before treatment, resulting in substandard anchoring performance.
[0003] Currently, some technologies in this field propose using smooth steel strands to manufacture steel strands for geotechnical anchor cables, solving the aforementioned problems by encasing the cut steel strands in PE pipes. However, in actual production, the manufacture of geotechnical anchor cables using smooth steel strands is mostly done manually. For example, after cutting the PE pipes and steel strands to a fixed length, manual application or simple equipment is used to apply oil to the steel strands and then encapsulate them in PE pipes. Furthermore, each process requires manual labor and transport equipment. For instance, after the steel strands are cut to a fixed length, manual operation of transport equipment is needed to move them to the oiling area, and after oiling, they are moved to the assembly area for PE pipe encapsulation. This process is not only time-consuming, but also prone to disordered placement during material handling, and even the grease on the steel strands may be scraped off, seriously affecting product quality. Therefore, there is an urgent need for a production line that enables integrated intelligent production of geotechnical anchor cables. Summary of the Invention
[0004] The technical problem to be solved by the present invention is to address the shortcomings of the existing technology by providing an integrated intelligent production line and control method for anchor cable factories, which realizes the automated production of unbonded steel strands.
[0005] The present invention discloses an integrated intelligent production line for an anchor cable factory, comprising a sliding platform and an assembly operating table; a cutting machine is provided between the sliding platform and the assembly operating table, an oil injection device is provided on one side of the cutting machine, and a clamping mechanism is provided between the oil injection device and the assembly operating table.
[0006] The sliding platform is equipped with a PE pipe feeding reel, a PE pipe pulling machine, and a PE pipe length fixing unit. The PE pipe feeding reel, PE pipe pulling machine, PE pipe length fixing unit, and cutting mechanism constitute an automatic PE pipe cutting production line. The sliding platform is also equipped with a steel strand pay-off reel, a steel strand traction machine, and a steel strand length fixing unit. The steel strand pay-off reel, steel strand traction machine, steel strand length fixing unit, cutting machine, oil injection device, and clamping mechanism constitute a steel strand oil injection sleeve production line.
[0007] Preferably, the sliding platform is equipped with an oil filling mechanism, which has a rigid oil pipe that can be inserted into the PE pipe and fill it with oil. The oil filling mechanism and the clamping mechanism together form an oil filling sub-production line for filling the PE pipe with oil.
[0008] Preferably, a chamfering machine is arranged in parallel with the cutting machine on one side, and the steel strand feeding reel, steel strand traction machine, steel strand length fixing unit, and chamfering mechanism form a steel strand chamfering sub-production line.
[0009] Preferably, the steel strand chamfering sub-production line and the PE pipe automatic pipe cutting production line execute their corresponding production processes synchronously.
[0010] Preferably, the cutting machine is equipped with a coding machine on the side near the sliding platform.
[0011] Preferably, the clamping mechanism consists of two openable half-clamping tubes and multiple clamping cylinders; the multiple clamping cylinders are installed between the oil injection device and the assembly operating table, and the two half-clamping tubes are respectively fixed on the two clamping arms of the clamping cylinders. When the two half-clamping tubes are closed, a PE pipe clamping channel is formed therein.
[0012] Preferably, the assembly operation table is provided with a groove for supporting PE pipe sections and / or steel strands. The groove is provided with multiple hook rods. A drive cylinder corresponding to each hook rod is installed on one side of the assembly operation table. The piston end of the drive cylinder is connected to the hook rod through a connector.
[0013] Preferably, an operating platform is provided on one side of the cable trough, and two cable support frames are provided at the discharge end of the operating platform. A wrapping machine and a cable guide machine are arranged in sequence between the two cable support frames. A cable laying machine is provided on the side of the cable support frame away from the assembly operating platform, and a coiling machine is provided on the side of the cable laying machine away from the cable support frame.
[0014] Preferably, a lifting platform is provided between the assembly operation table and the cable support frame, and a grouting tank is installed on one side of the lifting platform.
[0015] A control method for controlling the integrated intelligent production line of the anchor cable factory, the method comprising the following steps: Step 1: Initialize the sliding platform to enable the production line to form an automatic PE pipe cutting sub-line; Step 2: Perform an initialization process to set the length of the PE pipes located in the automatic PE pipe cutting sub-production line to zero. Step 3: Start the automatic PE pipe cutting sub-production line to cut the PE pipe to the set target length to obtain a PE pipe section; Step 4: Control the sliding platform to switch the production line to the steel strand oil injection sleeve production line, and then release the smooth steel strand. At the same time, use the oil injection device to inject oil into the smooth steel strand during the release until the smooth steel strand is oiled to the set oil injection section release length, and all the oiled smooth steel strand is inserted into the PE pipe section. Step 5: Continue to lay out the smooth steel strand to the target length, and then cut the smooth steel strand using the cutting machine to obtain the steel strand for rock and soil anchor cables.
[0016] Beneficial effects The advantages of this invention are: 1. This invention integrates four sub-production lines in the production line: an automatic PE pipe cutting sub-production line, a steel strand oil injection sleeve production line, an oil filling sub-production line, and a steel strand chamfering sub-production line. These four sub-production lines can be flexibly and automatically switched between each other. Through the coordinated operation of the four production lines, the automated production of unbonded steel strands required for the production of geotechnical anchor cables is realized. This solves the technical bottleneck of the inability to achieve automated production of unbonded steel strands in the field of geotechnical anchor cable production, greatly improves the production efficiency of geotechnical anchor cables, and reduces labor costs.
[0017] 2. The oiling of the steel strand of the present invention adopts the cooperation of an oiling device and a clamping device, which realizes the automated oiling of the unbonded section of the steel strand, and the smooth section of the steel strand after the oiling sleeve is not affected by the oiling. This not only simplifies the process flow, but also avoids the need for cleaning the smooth section.
[0018] 3. This invention adopts digital management and control and full life cycle traceability of products, realizing intelligent production of products and traceability of product production information, which can effectively improve the accuracy of product quality control. Attached Figure Description
[0019] Figure 1This is a schematic diagram of the structure of a rock and soil anchor cable.
[0020] Figure 2 A schematic diagram of the overall structure of the integrated intelligent production line for anchor cable factories according to the present invention.
[0021] Figure 3 This is a schematic diagram of the equipment layout in each sub-production line of the present invention.
[0022] Figure 4 This is a three-dimensional structural diagram of the oil injection device of the present invention.
[0023] Figure 5 This is a side view of the oil injection device of the present invention.
[0024] Figure 6 This is a schematic diagram of the oil filling mechanism of the present invention.
[0025] Figure 7 This is a schematic diagram of the rigid oil pipe extending in the oil filling mechanism of the present invention.
[0026] Figure 8 This is a schematic diagram of the steel strand structure for the rock and soil anchor cable of the present invention.
[0027] Figure 9 This is a schematic diagram of the side structure of the assembly operation table of the present invention.
[0028] Figure 10 This is a schematic diagram of the material hooking mechanism of the present invention.
[0029] Figure 11 This is a schematic diagram of the lifting platform structure of the present invention.
[0030] Figure 12 This is a schematic diagram of the equipment layout for the winding-coil process of the present invention.
[0031] Figure 13 This is a schematic diagram of the touch screen interface of the present invention.
[0032] The components are as follows: 1-Sliding platform, 2-Cutting machine, 3-Assembly operating table, 4-Control cabinet, 5-Oil injection device, 6-Chamfering machine, 8-Lifting platform, 9-Cable support frame, 10-Wrapping machine, 11-Cable guide machine, 12-Wire laying machine, 13-Coil forming machine, 14-Clamping cylinder II, 15-Half clamping pipe body, 16-Steel strand for rock and soil anchor cables, 17-Extrusion sleeve, 30-Wire trough, 31-Hook rod, 32-Operating platform, 33-Rail, 50-Installation platform, 51-Lifting cylinder, 52-Installation base. 53-Lower cover of oil chamber, 54-Upper cover of oil chamber, 55-Lifting cylinder, 56-Oil inlet, 57-Oil chamber sealing ring, 58-Clamping cylinder one, 59-Half pipe body, 80-Grouting tank, 81-Clamping mechanism, 101-PE pipe pay-off reel, 102-Steel strand pay-off reel, 103-PE pipe traction machine, 104-Steel strand traction machine, 105-Meter counter, 106-Coding machine, 107-Oil supply device, 108-Oil filling mechanism, 160-Smooth section, 161-Free section, 162-Heat shrink tubing. Detailed Implementation
[0033] The present invention will be further described below with reference to embodiments, but this does not constitute any limitation on the present invention. Any limited modifications made by any person within the scope of the claims of the present invention are still within the scope of the claims of the present invention.
[0034] Example 1 See Figure 2 and Figure 3 This invention discloses an integrated intelligent production line for an anchor cable factory, comprising a sliding platform 1 and an assembly operating table 3. The sliding platform 1 can move laterally along the vertical direction of the assembly operating table 3 to facilitate switching between sub-production lines. The assembly operating table 3 supports the cut PE pipes or steel strands and, in conjunction with a lifting platform 8, performs extrusion sleeve 17 installation or grouting treatment on the smooth section 160 of the steel strand. A cutting machine 2 is located between the sliding platform 1 and the assembly operating table 3 for cutting the PE pipes or steel strands. An oil injection device 5 is located on one side of the cutting machine 2 for injecting oil into the steel strands at a set oil pressure. A clamping mechanism is located between the oil injection device 5 and the assembly operating table 3 to clamp the cut PE pipes, facilitating the threading of the steel strands.
[0035] The production line in this embodiment mainly includes four sub-production lines: an automatic PE pipe cutting sub-production line, a steel strand oil injection sleeve production line, an oil filling sub-production line, and a steel strand chamfering sub-production line. The execution sequence of these four sub-production lines is as follows: the automatic PE pipe cutting sub-production line and the steel strand chamfering sub-production line execute their production processes simultaneously, followed by the oil filling sub-production line, and finally the steel strand oil injection sleeve production line. Through the coordinated operation of these four sub-production lines, the automated production of the steel strand 16 required for producing geotechnical anchor cables is achieved. This solves the technical bottleneck of the inability to achieve automated production of steel strand 16 for geotechnical anchor cables in the field of geotechnical anchor cable production, greatly improving the production efficiency of geotechnical anchor cables and reducing labor costs. The specific structure of each sub-production line will be described below.
[0036] First, let's introduce the automatic pipe cutting production line for PE pipes.
[0037] In this embodiment, the sliding platform 1 is equipped with a PE pipe feeding reel 101, a PE pipe traction machine 103, and a PE pipe length fixing unit. The PE pipe feeding reel 101, PE pipe traction machine 103, PE pipe length fixing unit, and cutting machine 2 constitute an automatic PE pipe cutting sub-production line. That is, the PE pipe traction machine 103 pulls and feeds the PE pipe in the PE pipe feeding reel 101, the PE pipe length fixing unit automatically fixes the length of the fed pipe, and the cutting machine 2 cuts the fixed-length PE pipe, thus realizing the automatic feeding and cutting of PE pipes.
[0038] In the automatic PE pipe cutting production line, the PE pipe feeding reel 101, PE pipe traction machine 103, and cutting machine 2 all use existing equipment, so they will not be described in detail. The PE pipe length-fixing unit consists of a high-precision meter counter 105 and a coding machine 106. The meter counter 105 is used to collect the conveyed length of the PE pipe in real time and synchronously link the cutting machine 2 to cut the PE pipe according to the conveyed length. Once the PE pipe reaches the target length, the conveying stops, and then the cutting machine 2 is started to cut the PE pipe, ensuring that the cutting length error is ≤±10mm. During the conveying process, after the PE pipe reaches the set length threshold, it will be coded by the coding machine 106 for traceability. For example, a traceability code is coded once per meter. The traceability code rule can be set as: "Raw material batch + production date + production line number + meter mark". For example, “GJ202405-20241001-ZB01-01”, where “GJ202405” is the batch number of the steel strand, “20241001” is the production date, “ZB01” is the production line number 1, and “01” is the first meter.
[0039] Next, the production line for the oil injection sleeve of steel strand will be introduced.
[0040] In this embodiment, the sliding platform 1 is also equipped with a steel strand pay-off reel 102, a steel strand traction machine 104, and a steel strand length-fixing unit. The steel strand pay-off reel 102, steel strand traction machine 104, steel strand length-fixing unit, cutting machine 2, oiling device 5, clamping mechanism, and assembly operating table 3 constitute a steel strand oiling and tubing production line. Specifically, the steel strand traction machine 104 pulls and pays off the steel strands from the steel strand pay-off reel 102, the steel strand length-fixing unit automatically sets the pay-off length, and the cutting machine 2 cuts the lengthened steel strands, thus achieving automatic pay-off and cutting of the steel strands. Furthermore, during the pay-off process, for the unbonded sections of the steel strands (i.e., the sections on the steel strands that need to be fitted with PE tubing), the cooperation between the steel strand length-fixing unit, the oiling device 5, and the clamping mechanism enables automatic oiling and tubing treatment of the unbonded sections.
[0041] In the steel strand oil injection sleeve production line, the steel strand pay-off reel 102 and steel strand traction machine 104 both utilize existing equipment. The cutting machine 2, shared by both the main production line and the PE pipe automatic cutting production line, improves equipment reusability and reduces overall production line design costs. The steel strand length-fixing unit also includes a high-precision meter counter 105 and a coding machine 106. The meter counter 105 collects the real-time conveying length of the steel strand and synchronously links the cutting machine 2 to cut the steel strand according to the conveying length. Once the steel strand reaches the target length, transmission stops, and the cutting machine 2 is started to cut the steel strand, resulting in the steel strand 16 for rock and soil anchor cables. During cutting, the cutting length error must be ensured to be ≤±10mm to meet the accuracy requirements for anchor cable length in complex geological engineering. During the conveying process, once the steel strand reaches the set length threshold, it will be coded by the coding machine 106. The specific design can refer to the coding design of PE pipes.
[0042] Since the length determination of steel strand and PE pipe needs to be carried out simultaneously during the production process, the meter counters 105 of the two length determination units need to be arranged independently and cannot be reused. However, the coding machine 106 can be reused. Therefore, the coding machine 106 can be installed in a fixed position, that is, the coding machine 106 is arranged on one side of the cutting machine 2 and does not move with the sliding platform 1. In this way, when determining the length of PE pipe or steel strand, coding can be performed on the PE pipe or steel strand according to the set length, so as to facilitate the traceability of information source of the geotechnical anchor cable through the code mark in the future.
[0043] like Figure 4 and Figure 5As shown, the oil injection device 5 includes a mounting platform 50, a lifting cylinder 51, an upper oil chamber cover 54, a lower oil chamber cover 53, and an oil supply device 107. The mounting platform 50 is located between the cutting machine 2 and the assembly operating platform 3. The lifting cylinder 51 is fixedly mounted on the mounting platform 50, and the piston end of the lifting cylinder 51 is fixedly connected to the lower oil chamber cover 53 through the mounting seat 52. The lifting cylinder 51 can raise and lower the upper oil chamber cover 54 and the lower oil chamber cover 53. When manufacturing PE pipe sections, the oil injection device 5 is not needed. Therefore, the upper oil chamber cover 54 and the lower oil chamber cover 53 are lowered to a position that will not affect the manufacturing of PE pipe sections by the lifting cylinder 51. When injecting oil into the steel strand, the upper oil chamber cover 54 and the lower oil chamber cover 53 can be raised to the target position to inject oil into the steel strand. The upper cover 54 of the oil chamber is fitted over the lower cover 53 of the oil chamber. A lifting cylinder 55 is installed on one side of the mounting base 52. The piston end of the lifting cylinder 55 is connected to the upper cover 54 of the oil chamber and is used to drive the upper cover 54 of the oil chamber to move, so as to achieve its closing and opening with the lower cover 53 of the oil chamber. The upper cover 54 of the oil chamber is provided with an oil inlet 56, which is connected to the oil supply device 107 through an oil supply pipe.
[0044] When the upper cover 54 and the lower cover 53 of the oil chamber are closed, an oil chamber is formed therein, and the steel strand is inserted into the oil chamber. At this time, the oil supply device 107 injects grease into the oil chamber through the oil inlet 56. Since the oil chamber is in a closed state, as the oil chamber is filled with grease, pressurized grease can be formed in the oil chamber, so that the grease can evenly fill the gaps between the steel wires of the steel strand, realizing automatic oiling of the steel strand.
[0045] In the oil supply device 107, a gear pump / plunger pump is used to quantitatively pressurize and inject oil, and the oil injection volume is precisely controlled at 50-100g / m (compliant with JG / T 161 standard) to ensure that the grease evenly covers the surface of the steel strand.
[0046] In this embodiment, when the upper cover 54 of the oil chamber is closed on the lower cover 53 of the oil chamber, oil chamber sealing rings 57 are formed at both ends of the oil chamber. The oil chamber sealing rings 57 are fitted with the steel strands with a gap. This not only forms a good sealing effect on the oil chamber with the steel strands inserted and reduces the amount of grease leakage, but also enables the steel strand traction machine 104 to continuously push the steel strands and coat them with grease.
[0047] In addition, to improve the straightness of the steel strand and the stability of its conveying during pipe threading, the oil injection device 5 in this embodiment also includes a guide mechanism consisting of two openable half-pipes 59 and a clamping cylinder 58. The openable half-pipes 59 facilitate the installation of the steel strand, and the guide mechanism can be opened during the fabrication of PE pipe sections to prevent it from interfering with the fabrication process. The clamping cylinder 58 is mounted on a mounting platform 50 on the side away from the assembly worktable 3. The two half-pipes 59 are respectively fixed to the two clamping arms of the clamping cylinder 58, and a steel strand guide channel is formed when the two half-pipes 59 are closed.
[0048] The clamping mechanism in this embodiment consists of two openable half-clamping tube bodies 15 and multiple clamping cylinders 14. The multiple clamping cylinders 14 are mounted on a mounting platform 50 near the assembly worktable 3. The two half-clamping tube bodies 15 are respectively fixed to the two clamping arms of the clamping cylinders 14. When the two half-clamping tube bodies 15 are closed, a PE pipe clamping channel is formed. When the two half-clamping tube bodies 15 are closed, the cut PE pipe is clamped in the PE pipe clamping channel. The PE pipe clamping channel is coaxial with the steel strand guide channel, so when the steel strand is pushed, it can be effectively inserted into the PE pipe.
[0049] The following will introduce the oil filling production line.
[0050] In this embodiment, the sliding platform 1 is also equipped with an oil filling mechanism 108, which is located between the two traction machines. The oil filling mechanism 108, together with the clamping mechanism and the assembly operating table 3, constitutes an oil filling sub-production line for filling the PE pipe with oil. The oil filling sub-production line executes its production process immediately after the PE pipe is cut. The purpose of filling the PE pipe with grease is to pre-fill the PE pipe with grease. The grease pre-filled in the PE pipe compensates for the insufficient amount of grease on the surface of the steel strand during the threading process, thereby ensuring the uniformity of the amount of grease between the steel strand and the PE pipe.
[0051] like Figures 6-7As shown, the oil filling mechanism 108 in this embodiment includes an oil filling pipe 1081, a cylinder 1082, a rigid oil pipe 1083, a support slide plate 1084, a slide rail 1085, a support plate 1086, and an oil receiving groove 1087. Cylinder 1082 and slide rail 1085 are both mounted on sliding platform 1 via brackets. Support slide plate 1084 is slidably mounted on slide rail 1085. The piston rod of cylinder 1082 is fixed to one side of support slide plate 1084. Rigid oil pipe 1083 is fixed to the other side of support slide plate 1084. Support plate 1086 is mounted at the end of slide rail 1085. Oil receiving groove 1087 is mounted below support plate 1086. Rigid oil pipe 1083 has a hollow structure and both ends of rigid oil pipe 1083 are closed. Multiple oil passage holes are opened on the wall of rigid oil pipe 1083. Oil injection pipe 1081 is mounted on support slide plate 1084 and is connected to the inner cavity of rigid oil pipe 1083. The support slide plate 1084 can slide on the slide rail 1085, driving the rigid oil pipe 1083 to retract and push; the support plate 1086 supports the rigid oil pipe 1083, and can also wipe off excess grease on the oil pipe and store it in the oil receiving groove 1087.
[0052] In the specific design, the rigid oil pipe 1083 is approximately one meter long and can be a hollow pipe with an outer diameter of 10mm and an outer diameter of 7mm. One end is connected to the oil injection pipe 1081, and the other end is inserted into the PE pipe section. When the cylinder 1082 is started, the rigid oil pipe 1083 is inserted into the clamped PE sleeve, and then grease is injected into the PE pipe section approximately one meter from the insertion section for a metered oil injection operation. After the oil injection operation is completed, the rigid oil pipe 1083 is retracted. When threading the steel strand, since there is no pre-filled grease in the first section of the PE pipe section (i.e., the first meter), the grease on the steel strand itself mainly fills the gap between the steel strand and the PE pipe section during threading, which will cause grease loss in the first section of the steel strand. When the end of the steel strand comes into contact with the grease in the PE pipe section, this pre-filled grease replenishes the grease lost on the steel strand or the portion lacking grease between the steel strand and the PE pipe section. Excess pre-filled grease is continuously pushed forward by the steel strand, compensating for the amount of grease between the steel strand and the PE pipe section during this process. Therefore, this method compensates for the grease loss on the steel strand caused by scraping off the inner wall of the pipe.
[0053] Finally, the steel strand chamfering production line is introduced.
[0054] A chamfering machine 6 is arranged parallel to the cutting machine 2 on one side. The chamfering machine 6 is located on one side of the cutting machine 2 and is used to chamfer the ends of the steel strands to facilitate the steel strands being threaded into the PE pipes, while also preventing damage to the PE pipes during the threading process. The steel strand pay-off reel 102, the steel strand traction machine 104, the steel strand length fixing unit, and the chamfering machine 6 constitute the steel strand chamfering sub-production line.
[0055] In this embodiment, the steel strand chamfering sub-production line and the PE pipe automatic cutting sub-production line execute their production processes synchronously. Specifically, when the PE pipe automatic cutting sub-production line is feeding PE pipes, the steel strand chamfering sub-production line is also feeding steel strands. However, at this time, the feeding length of the steel strands is limited to the ends of the steel strands that can be chamfered by the chamfering machine 6. After the chamfering is completed, the feeding is immediately followed by winding and resetting, waiting for the sub-production line to switch.
[0056] The aforementioned four sub-production lines, as the front-end production process of the production line, realize the automated production of the steel strand 16 required for geotechnical anchor cables. In this invention, as... Figure 8 The diagram shows a steel strand 16 for rock and soil anchor cables. The steel strand 16 for rock and soil anchor cables consists of a smooth section 160, a free section 161, and a heat shrink tubing 162. The subsequent processes of the production line will be introduced next.
[0057] like Figure 9 As shown, the assembly workbench 3 has a wire trough 30 on one side. This wire trough 30 is used to support a single steel strand, facilitating the production of the steel strand by the sub-production line. In addition, a scale is also provided in the wire trough 30 for measuring the cut material. The measurement result is compared with the meter reading of the meter counter to determine whether the error of the current material meets the requirements.
[0058] After the steel strand is produced, it needs to be removed from the wire trough 30. To solve this problem, such as... Figure 10 As shown, the assembly platform 3 in this embodiment is equipped with multiple hook rods 31 for hooking the steel strand after the oil-filled sleeve is removed from the wire trough 30. The assembly platform 3 is also equipped with drive cylinders 32 corresponding to the hook rods 31. The piston end of the drive cylinder 32 is connected to the hook rod 31 through a connector. The hook rod 31 is generally L-shaped and can be inserted into the wire trough 30. The width of its crossbar section matches the bottom width of the wire trough 30, and the surface of the crossbar section is a sloped structure. When the drive cylinder 32 drives the hook rod 31 to rise, the hook rod 31 will drive the steel strand to rise. When the crossbar of the hook rod 31 rises above the wire trough 30, the steel strand falls down along the slope into the operating platform 32 under its own gravity, thereby realizing automatic material handling.
[0059] After the oil-filled steel strand is hooked into the operating platform 32, in order to prevent grease from overflowing from the PE pipe end of the steel strand, a heat-shrink sleeve 162 needs to be applied between the PE pipe end and the smooth section for sealing. Specifically, the heat-shrink sleeve 162 is placed between the PE pipe end and the smooth section 160, and then a hot air gun is used to heat-shrink the heat-shrink sleeve 162.
[0060] After the casing is processed, the ends of the steel strands after the oil-filled casing, i.e., the smooth section 160, can be treated. For example, for tension-type geotechnical anchor cables, end casting is required on the smooth section 160 of the steel strands. Figure 11 As shown, for ease of pouring, a lifting platform 8 is provided at the end of the assembly operation platform 3 away from the sliding platform 1, and a grouting tank 80 is installed on one side of the lifting platform 8. After the cable passes over the lifting platform 8, its end is inserted into the grouting tank 80, and the cable is fixed and positioned by the clamping mechanism 81. Then, grout is poured into the grouting tank 80, and after it solidifies, a degrouting process is performed to complete the grouting process, thereby obtaining unbonded steel strands for producing tensile geotechnical anchor cables, namely, geotechnical anchor cable steel strand 16. After obtaining the geotechnical anchor cable steel strand 16, the anchor cable assembly can be performed. The assembly of tensile geotechnical anchor cables only requires installing multiple unbonded steel strands on the wire splitter and fixing them according to the process requirements, and then performing corresponding processing on their ends to form tensile geotechnical anchor cables. Since this invention does not improve these process steps, further discussion is not required.
[0061] Through the above steps of producing unbonded steel strand and assembling anchor cables, the finished rock and soil anchor cables are obtained. Finally, the rock and soil anchor cables are wound and packaged.
[0062] Regarding the winding and packaging of anchor cables, this invention provides a production line for the automatic winding and packaging of rock and soil anchor cables. Specifically, as follows... Figure 12 As shown, the discharge end of the operating platform 32 is equipped with two cable support frames 9 for supporting the soil and rock anchor cables. Each cable support frame 9 mainly consists of a frame and nylon rollers rotatably mounted within it. The soil and rock anchor cables are positioned on the nylon rollers, providing support and passive transport. Between the two cable support frames 9, a wrapping machine 10 and a cable guide machine 11 are arranged sequentially. The cable guide machine 11 corrects the direction of the soil and rock anchor cables after wrapping, ensuring the cables correspond to the positions of the cable laying machine 12. The cable laying machine 12 is located on the side of the cable support frame 9 furthest from the assembly operating platform 3, and a coiling machine 13 is located on the side of the cable laying machine 12 furthest from the cable support frame 9. The soil and rock anchor cables undergo wrapping by the wrapping machine 10 and coiling by the coiling machine 13, thus completing the entire production process. The wrapping machine 10 uses a two-in-one waterproof non-woven fabric (non-woven fabric + waterproof tape) for protective wrapping, with an overlap rate of ≥30%, ensuring that the cable is fully wrapped without any exposed areas. The coiling machine 13 is driven by a geared motor, and the inner diameter of the coil can be adjusted according to the anchor cable specifications, ranging from 800-1800mm. After coiling, a QR code label is affixed to the surface of the cable, containing information such as product specifications, production batch, and test data, enabling full lifecycle traceability.
[0063] The workflow of the aforementioned automated winding and packaging production line is as follows: One end of the cable is passed through one cable support frame 9, and then sequentially through the wrapping machine 10, the cable guide machine 11, another cable support frame 9, and the winding machine 12, finally fixing its end in the coiling machine 13. During this process, manual threading is required, and the cable portion between the coiling machine 13 and the wrapping machine 10 must first be wrapped. Next, the wrapping machine 10 evenly wraps the two-in-one waterproof non-woven fabric (non-woven fabric + waterproof tape) around the cable. The cable is precisely conveyed to the winding machine 12 via the cable guide machine 11, and the coiling machine 13 rotates to form a coil. The winding machine 12 is used to adjust the height of the cable to ensure that the inner and outer diameters of the coiled cable meet the process requirements, ultimately achieving automated wrapping and coiling operations.
[0064] The production line of this invention also includes a control cabinet 4. The control cabinet 4 is equipped with a visual touchscreen, a PLC control system, and a data management system. The PLC control system is used to control various devices, enabling the distribution of production parameters, monitoring of equipment status, and alarm for abnormalities. The visual touchscreen can collect equipment operating parameters (such as cutting length) and production progress (output, process completion rate) in real time, and allows for the input of various parameters; one of the interfaces is shown below. Figure 13 As shown, the data management system adopts a dual coding system of "batch code + single QR code" to link data from all stages, including raw material entry (steel strand batch, anchor certificate of conformity), production process (parameters of each process), and quality inspection (tensile test data). It also provides QR codes, which can be scanned to view complete traceability information. Example 2 A control method for controlling the aforementioned integrated intelligent production line of an anchor cable factory, the method comprising the following steps: Step 1: Initialize sliding platform 1 to create an automatic PE pipe cutting sub-production line and a steel strand chamfering sub-production line within the production line, facilitating the synchronous start-up of these two sub-production lines in the future.
[0065] Step 2: Perform initialization processing to set the length to zero for the PE pipes in the automatic PE pipe cutting sub-production line and the steel strands in the steel strand chamfering sub-production line.
[0066] Specifically, the PE pipes located on the PE pipe pay-off reel 101 are sequentially installed on the PE pipe traction machine 103 and the meter counter 105 in the PE pipe length-fixing unit. At the same time, the steel strands located on the steel strand pay-off reel 102 are sequentially installed on the steel strand traction machine 104 and the meter counter 105 in the steel strand length-fixing unit. The lengths of the PE pipes and steel strands are then initialized to zero.
[0067] To achieve the zeroing operation, a limit switch is installed on one side of the meter counter 105 in the production line of this invention as a zero point. Specifically, when the traction machine pulls the PE pipe or steel strand to the limit switch and triggers the limit switch, the length of the PE pipe or steel strand is considered to be zero at this time.
[0068] Step 3: Start the automatic PE pipe cutting sub-production line to cut the PE pipe to the set target length; at the same time, start the steel strand chamfering sub-production line to chamfer the ends of the steel strands, and reset the steel strands after the chamfering is completed.
[0069] Specifically, the PE pipe pulling machine 103 lays out the PE pipe, and after the pipe reaches the target length, it clamps both ends of the PE pipe at the cutting machine 2, then starts the cutting machine 2 to cut the PE pipe. Simultaneously, the chamfering machine 6 is started, and the steel strand pulling machine 104 lays out the steel strand into the chamfering machine 6 to chamfer the ends of the steel strand. After the PE pipe is cut, the clamping mechanism continues to hold the PE pipe segment, while the PE pipe in the automatic pipe cutting sub-production line is reset; similarly, after the steel strand in the steel strand chamfering sub-production line is chamfered, the steel strand in that sub-production line is reset. This step achieves synchronous operation of the two sub-production lines, realizing the simultaneous execution of PE pipe cutting and steel strand chamfering pre-processing.
[0070] Step 4: Control the sliding platform 1 to switch the production line to the oil filling sub-production line, and start the oil filling sub-production line to fill the inside of the cut PE pipe with oil. After the oil filling is completed, proceed to Step 5.
[0071] Step 5: Control the sliding platform 1 to switch the production line to the steel strand oil injection sleeve production line, and then release the smooth steel strand so that it passes through the guide mechanism and is inserted into the oil injection device 5. The oil injection device 5 injects oil into the smooth steel strand until the smooth steel strand is oiled to the set oil injection section release length, and all the oiled smooth steel strand is inserted into the PE pipe section.
[0072] Step 6: Lay out the steel strand to the target length, and then cut the steel strand using the cutting machine 2 to obtain the target length of the rock and soil anchor cable steel strand 16.
[0073] Through the above process steps, the automated production of the steel strand 16 required for producing geotechnical anchor cables was achieved.
[0074] Step 7: Perform grouting and curing treatment on the smooth section at the end of the steel strand 16 for the rock and soil anchor cable.
[0075] Step 8: Install the wire splitting disc and accessories on the geotechnical anchor cable after grouting treatment using steel strand 16 to complete the assembly of the anchor cable; then carry out wrapping and coiling treatment to complete the entire process of geotechnical anchor cable production.
[0076] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention, and these will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.
Claims
1. An integrated intelligent production line for an anchor cable factory, characterized in that, It includes a sliding platform (1) and an assembly operating table (3); a cutting machine (2) is provided between the sliding platform (1) and the assembly operating table (3), an oil injection device (5) is provided on one side of the cutting machine (2), and a clamping mechanism is provided between the oil injection device (5) and the assembly operating table (3); The sliding platform (1) is equipped with a PE pipe feeding reel (101), a PE pipe traction machine (103) and a PE pipe length fixing unit. The PE pipe feeding reel (101), the PE pipe traction machine (103), the PE pipe length fixing unit and the cutting machine (2) constitute an automatic PE pipe cutting sub-production line. The sliding platform (1) is also equipped with a steel strand pay-off reel (102), a steel strand traction machine (104), and a steel strand length fixing unit. The steel strand pay-off reel (102), steel strand traction machine (104), steel strand length fixing unit, cutting machine (2), oil injection device (5), and clamping mechanism constitute a steel strand oil injection sleeve production line.
2. The integrated intelligent production line for anchor cable factories according to claim 1, characterized in that, The sliding platform (1) is equipped with an oil filling mechanism (108), which has a rigid oil pipe (1083) that can be inserted into the PE pipe and fill it with oil. The oil filling mechanism (108) and the clamping mechanism form an oil filling sub-production line for filling the PE pipe with oil.
3. The integrated intelligent production line for anchor cable factories according to claim 1, characterized in that, The cutting machine (2) is provided with a chamfering machine (6) arranged in parallel with it on one side. The steel strand pay-off reel (102), steel strand traction machine (104), steel strand length fixing unit, and chamfering machine (6) constitute a steel strand chamfering sub-production line.
4. The integrated intelligent production line for anchor cable factories according to claim 3, characterized in that, The steel strand chamfering sub-production line and the PE pipe automatic pipe cutting production line execute their corresponding production processes synchronously.
5. The integrated intelligent production line for anchor cable factories according to claim 1, characterized in that, The cutting machine (2) is equipped with a coding machine (106) on the side near the sliding platform (1).
6. The integrated intelligent production line for anchor cable factories according to claim 1, characterized in that, The clamping mechanism consists of two openable half-clamping tubes (15) and multiple clamping cylinders (14); the multiple clamping cylinders (14) are installed between the oil injection device (5) and the assembly operation table (3), the two half-clamping tubes (15) are respectively fixed on the two clamping arms of the clamping cylinders (14), and a PE pipe clamping channel is formed when the two half-clamping tubes (15) are closed.
7. The integrated intelligent production line for anchor cable factories according to claim 1, characterized in that, The assembly operation table (3) is provided with a wire groove (30) for carrying PE pipe sections and / or steel strands. The wire groove (30) is provided with multiple hook rods (31). A drive cylinder (32) corresponding to each hook rod (31) is installed on one side of the assembly operation table (3). The piston end of the drive cylinder (32) is connected to the hook rod (31) through a connector.
8. The integrated intelligent production line for anchor cable factories according to claim 7, characterized in that, An operating platform (32) is provided on one side of the trough (30). Two cable support frames (9) are provided at the discharge end of the operating platform (32). A wrapping machine (10) and a cable guide machine (11) are arranged in sequence between the two cable support frames (9). A cable laying machine (12) is provided on the side of the cable support frame (9) away from the assembly operating table (3). A coiling machine (13) is provided on the side of the cable laying machine (12) away from the cable support frame (9).
9. The integrated intelligent production line for anchor cable factories according to claim 7, characterized in that, A lifting platform (8) is provided between the assembly operation table (3) and the cable support frame (9), and a grouting tank (80) is installed on one side of the lifting platform (8).
10. A control method for controlling the integrated intelligent production line of the anchor cable factory as described in claim 1, characterized in that, The method includes the following steps: Step 1: Initialize the sliding platform (1) to enable the production line to form an automatic PE pipe cutting sub-line; Step 2: Perform an initialization process to set the length of the PE pipes located in the automatic PE pipe cutting sub-production line to zero. Step 3: Start the automatic PE pipe cutting sub-production line to cut the PE pipe to the set target length to obtain a PE pipe section; Step 4: Control the sliding platform (1) to switch the production line to the steel strand oil injection sleeve production line, and then release the smooth steel strand. At the same time, use the oil injection device (5) to inject oil into the smooth steel strand during the release until the smooth steel strand is oiled to the set oil injection section release length, and all the oiled smooth steel strand is inserted into the PE pipe section. Step 5: Continue to lay out the smooth steel strand to the target length, and then cut the smooth steel strand using the cutting machine (2) to obtain the steel strand (16) for rock and soil anchor cable.