A precast beam combined u-shaped rib and a production line and method thereof

Abstract

This invention discloses a precast beam composite U-shaped reinforcement, its production line, and production method. The U-shaped reinforcement body includes web stirrups and bottom slab stirrups. Two web stirrups are arranged symmetrically and obliquely. The bottom slab stirrups are placed on the two web stirrups. A positioning steel mesh is included, comprising a web positioning mesh and bottom slab positioning short bars. This invention automates the cutting of the positioning steel mesh through the entire production line setup. The positioning steel mesh is then welded and joined with the stirrups to complete the processing of the integrally formed web stirrups. After processing, it is transferred to a U-shaped reinforcement welding platform for assembly and welding with the bottom slab stirrups and bottom slab positioning steel bars to obtain the assembled U-shaped reinforcement. This method automates the forming and processing of the positioning mesh, the welding of the stirrups, and the assembly of the U-shaped reinforcement, solving industry pain points such as poor positioning accuracy, high labor input, and unstable product quality associated with manual installation.

Description

Technical Field

[0001] This invention relates to the field of automated processing technology for precast beam steel reinforcement cages, and in particular to a precast beam composite U-shaped reinforcement, its production line, and production method. Background Technology

[0002] Positioning rebar mesh is a sheet-like mesh structure formed by welding positioning long and short bars into the precast beam's rebar skeleton system. Each sheet is welded and fixed to the ordinary rebar skeleton of the beam according to the design requirements, providing precise and secure spatial positioning for the prestressing tendons (corrugated pipes). It ensures accurate "coordinates" and straight lines of the tendons, serving as an "invisible skeleton" to guarantee the safety and durability of the precast beam.

[0003] In the field of precast beams, there is no prestressed tendon positioning steel mesh. The positioning of the prestressed tendons relies entirely on the workers to install the positioning steel bars on site. The installation accuracy depends entirely on the experience of the workers on site. The local prestressing position deviation is greater than 5cm. Not only is the deviation large, but it also depends entirely on the experience of the workers. This not only requires a large amount of manpower, but also results in unstable output. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings mentioned above by providing a precast beam composite U-shaped reinforcement, its production line, and production method, thereby achieving automatic processing and forming of prestressed tendon positioning steel mesh.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: a precast beam composite U-shaped reinforcement, comprising: The U-shaped reinforcement body includes web stirrups and bottom plate stirrups. The number of web stirrups is two and they are arranged symmetrically and obliquely. The bottom plate stirrups are arranged on the two web stirrups. The positioning reinforcement mesh includes a web positioning mesh and a bottom plate positioning short bar. The web positioning mesh is welded to the web stirrups, and the bottom plate positioning short bar is welded to the bottom plate stirrups.

[0006] A production line for precast beam composite U-shaped reinforcement, based on the precast beam composite U-shaped reinforcement as described in the claims, is characterized by comprising: A straightening and cutting mechanism is located at the front end of the production line to straighten and cut the long ribs of the web positioning mesh, the short ribs of the web positioning mesh, and the short ribs of the bottom plate positioning mesh. A rebar buffering mechanism is located in the first buffer area of ​​the production line to buffer the long bars of the web positioning mesh, the short bars of the web positioning mesh, and the short bars of the bottom plate positioning mesh. The material conveying mechanism is mounted on the rebar buffer mechanism and is connected to the output port of the straightening and cutting mechanism to convey the rebar produced by the straightening and cutting mechanism to the corresponding buffer mechanism. A long rib extrusion mechanism is located at the long rib processing station of the production line, used to receive long ribs from the rebar buffer mechanism and bend and extrude the long ribs into shape. A steel mesh welding mechanism is located at the first welding station of the production line to realize the welding of steel mesh. The U-rib assembly and welding mechanism is located at the second welding station of the production line and is used to realize the assembly and welding of U-ribs. A U-shaped reinforcement buffer mechanism is located in the second buffer area of ​​the production line to buffer the U-shaped reinforcement. The material silos are two in number and are both located in the material storage area of ​​the production line, for storing the web stirrups and the bottom stirrups. The feeding and discharging mechanism is located above the first buffer area, the long rib processing station, the first welding station, the second welding station, the second buffer area, and the material storage area, and is used to realize the feeding, discharging, and transfer of various materials.

[0007] Furthermore, the rebar caching mechanism includes a long rebar caching mechanism, a web short rebar caching mechanism, and a bottom slab rebar caching mechanism arranged sequentially from left to right. The long rebar caching mechanism is a horizontally arranged chain structure with permanent magnets on it. The web short rebar caching mechanism and the bottom slab rebar caching mechanism are both horizontally arranged chain structures with permanent magnets on them.

[0008] Furthermore, the material conveying mechanism includes a steel bar conveying mechanism disposed on three buffer mechanisms and connected to the output port of the straightening and cutting mechanism. The steel bar conveying mechanism is provided with a pushing mechanism corresponding to the three buffer mechanisms. The steel bar conveying mechanism is a conveying chain, and a permanent magnet is disposed on the chain structure.

[0009] Furthermore, the steel mesh welding mechanism includes a pallet moving track and a resistance welding machine. The resistance welding machine is located on the side of the pallet moving track, with the upper electrode of the resistance welding machine located above the pallet moving track and the lower electrode located below the pallet moving track. A welding pallet body is provided on the pallet moving track, and the welding pallet body moves along the pallet moving track.

[0010] Furthermore, the welding pallet body is equipped with a drive motor, a bracket movement guide rail, and a stirrup positioning cylinder. A stirrup adjustment positioning bracket is slidably arranged on the bracket movement guide rail, and a plurality of positioning net adjustment positioning brackets are slidably arranged on the bracket movement guide rail, with the plurality of positioning net adjustment positioning brackets located on the side of the stirrup adjustment positioning bracket. Both the welding tray body and the stirrup spacing adjustment and positioning bracket are equipped with stirrup positioning modules.

[0011] Furthermore, the U-rib assembly welding mechanism includes a U-rib assembly platform and a welding machine ground rail. The welding machine ground rail is located on the side of the U-rib assembly platform, and an assembly resistance welding machine is slidably mounted on the welding machine ground rail. The welding part of the assembly resistance welding machine can move to above the U-rib assembly platform. The U-shaped reinforcement assembly platform is equipped with two bottom web plate clamping cylinders, the U-shaped reinforcement assembly platform is equipped with a bottom plate positioning steel bar bracket located between the two bottom web plate clamping cylinders, and the U-shaped reinforcement assembly platform is equipped with a bottom plate cylinder located between the bottom plate positioning steel bar brackets. The U-shaped reinforcement assembly platform is also equipped with a bottom plate stirrup positioning slot and a web plate forming stirrup positioning slot.

[0012] Furthermore, the feeding and discharging mechanism includes two gantry tracks, on which a first gantry, a second gantry, and a third gantry are slidably arranged from left to right. A first gripper mechanism is provided on the first gantry, a second gripper mechanism is provided on the second gantry, and a third gripper mechanism is provided on each of the third gantry tracks.

[0013] Furthermore, the first gripper mechanism includes a first gripper frame, on which a first servo module is disposed, and on both the first gripper frame and the first servo module a first magnetic gripper is disposed. The second gripper mechanism includes a second gripper frame, a second magnetic gripper is provided on the second gripper frame, a second servo module is provided on the second gripper frame, and a first cylinder gripper is provided on both the second gripper frame and the second servo module. The third gripper mechanism includes a third gripper frame, a third magnetic gripper is provided on the third gripper frame, a third servo module is provided on the third gripper frame, and a second cylinder gripper is provided on both the third gripper frame and the third servo module.

[0014] A method for producing precast beam composite U-shaped reinforcement, based on any one of the precast beam composite U-shaped reinforcement production lines, includes the following method: S1. The straightening and cutting mechanism is used to straighten and cut the long ribs of the web positioning mesh, the short ribs of the web positioning mesh, and the short ribs of the bottom plate positioning mesh respectively. S2. Then, the web positioning mesh long bars, web positioning mesh short bars, and bottom plate positioning short bars obtained from the production are transported to the corresponding steel bar buffering mechanism for buffering through the material conveying mechanism. S3. The long ribs of the web positioning mesh on the long rib buffer mechanism are grasped by the long rib extrusion mechanism and processed to achieve extrusion molding; S4. The long and short reinforcing bars of the web positioning mesh are gripped separately by the first gripper mechanism on the first gantry and transported to the main body of the welding tray. S5. The welding tray body is moved to the resistance welding machine to weld the long and short ribs. After welding, the web positioning mesh is obtained, and the welding tray body carries the welded web positioning mesh back to its original position. S6. Then, the second gripper mechanism on the first gantry grabs the web plate stirrups in the hopper and transfers them to the main body of the welding pallet. S7. The welding tray body is moved to the resistance welding machine again for welding to obtain the integrally formed stirrups of the web plate. S8. Then, the web plate integrally formed stirrups are grabbed and transported to the U-shaped reinforcement assembly platform by the third gripper mechanism on the third gantry. The bottom plate stirrups and bottom plate positioning short bars are grabbed and transported to the U-shaped reinforcement assembly platform by the second gripper mechanism on the second gantry. S9. The assembly resistance welding machine assembles and welds the web plate integrally formed stirrups, bottom plate stirrups and bottom plate positioning short bars on the U-bar assembly platform to obtain the assembled U-bar. S10. The assembly U-shaped reinforcement is grabbed by the third gripper mechanism on the third gantry and transported to the assembly U-shaped reinforcement buffer mechanism for buffering.

[0015] The beneficial effects of this invention are reflected in: In use, this invention achieves automated feeding of the positioning steel mesh through a straightening and cutting mechanism, a buffer mechanism, a conveying mechanism, a long bar extrusion mechanism, a steel mesh welding mechanism, a U-bar assembly and welding mechanism, an assembly U-bar buffer mechanism, and a feeding and discharging mechanism. Then, the positioning steel mesh is welded and joined with stirrups to complete the processing of the integrally formed stirrups for the web. After processing, it is transferred to the U-bar welding platform for assembly and welding with the bottom plate stirrups and bottom plate positioning steel bars to obtain the assembled U-bars. Through the above method, the forming and processing of the positioning mesh and the welding of the stirrups, as well as the automated processing of the assembled U-bars, are realized. During the assembly of the steel skeleton, workers directly install the assembled U-bars on the jig, achieving precise installation of the positioning mesh. This fundamentally solves the industry pain points of poor positioning accuracy, high labor input, and unstable product quality caused by manual installation of prestressed tendons. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the combined U-shaped reinforcement of the present invention; Figure 2 This is a schematic diagram of the overall production line structure of the present invention; Figure 3 This is a schematic diagram of part of the production line structure of the present invention; Figure 4 This is a schematic diagram of the steel mesh welding mechanism of the present invention; Figure 5 This is a schematic diagram of the structure of the welding tray body of the present invention; Figure 6 This is a schematic diagram of the U-rib assembly and welding mechanism of the present invention; Figure 7 This is a schematic diagram of the feeding and discharging mechanism of the present invention; Figure 8 This is a schematic diagram of the structure of the first gripper mechanism of the present invention; Figure 9 This is a schematic diagram of the structure of the second gripper mechanism of the present invention; Figure 10 This is a schematic diagram of the third gripper mechanism of the present invention.

[0017] In the picture: 1. Straightening and cutting mechanism; 2. Reinforcing bar buffering mechanism; 21. Long bar buffering mechanism; 22. Web short bar buffering mechanism; 23. Bottom slab reinforcing bar buffering mechanism; 3. Material conveying mechanism; 31. Rebar conveying mechanism; 32. Material pushing mechanism; 4. Long rib extrusion mechanism; 5. Steel mesh welding mechanism; 51. Pallet movement track; 52. Resistance welding machine; 53. Welding pallet body; 531. Drive motor; 532. Bracket motion guide rail; 533. Stirrup positioning cylinder; 534. Stirrup spacing adjustment positioning bracket; 535. Positioning net spacing adjustment positioning bracket; 536. Stirrup positioning module; 6. U-rib assembly and welding mechanism; 61. U-rib assembly platform; 62. Welding machine ground rail; 63. Assembly resistance welding machine; 611. Bottom and web plate clamping cylinder; 612. Bottom plate positioning rebar bracket; 613. Bottom plate cylinder; 614. Bottom plate stirrup positioning slot; 615. Web plate forming stirrup positioning slot; 7. Assembly U-shaped rib cache mechanism; 8. Silo; 9. Feeding and discharging mechanism; 91. Gantry track; 92. First gantry; 93. Second gantry; 94. Third gantry; 95. First gripper mechanism; 96. Second gripper mechanism; 97. Third gripper mechanism; 951. First gripper frame; 952. First servo module; 953. First magnetic gripper; 961. Second gripper frame; 962. Second magnetic gripper; 963. Second servo module; 964. First cylinder gripper; 971. Third gripper frame; 972. Third magnetic gripper; 973. Third servo module; 974. Second cylinder gripper; 10. U-shaped main reinforcement; 101. Web stirrups; 102. Web positioning mesh; 103. Bottom slab stirrups; 104. Bottom slab positioning short bars. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. Unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Please see Figure 1-10 This invention discloses a steel reinforcement cage for assembling U-shaped precast beams, comprising: U-shaped reinforcement body 10, which includes web stirrups 101 and bottom plate stirrups 102. There are two web stirrups 101 arranged symmetrically and obliquely. The bottom plate stirrups 102 are arranged on the two web stirrups 101. The positioning reinforcement mesh includes a web positioning mesh 103 and a bottom plate positioning short bar 104. The web positioning mesh 103 is welded to the web stirrups 101, and the bottom plate positioning short bar 104 is welded to the bottom plate stirrups 102.

[0020] A production line for precast beam composite U-shaped reinforcement includes: The straightening and cutting mechanism 1 is located at the front end of the production line. As the raw material preparation unit of the production line, the straightening and cutting mechanism 1 has a built-in CNC system. It can preset the cutting length and quantity of steel bars according to the box girder design drawings, and continuously complete the automated straightening and cutting of steel bars of different specifications without the need for manual repeated adjustment of parameters. It is adapted to the positioning steel bar processing requirements of box girders of different beam types and different spans, and is used to realize the automated straightening and fixed length cutting of the long bars of the web positioning mesh, the short bars of the web positioning mesh, and the short bars of the bottom plate positioning mesh 104.

[0021] The rebar buffer mechanism 2 is located in the first buffer area of ​​the production line and is used to buffer the long bars of the web positioning mesh, the short bars of the web positioning mesh, and the bottom plate positioning bars. The rebar buffering mechanism 2 includes a long rebar buffering mechanism 21, a web short rebar buffering mechanism 22, and a bottom plate rebar buffering mechanism 23 arranged sequentially from left to right. The long rebar buffering mechanism 21 is a chain structure arranged horizontally from left to right, and a permanent magnet is provided on the chain structure. The web short rebar buffering mechanism 22 and the bottom plate rebar buffering mechanism 23 are both chain structures arranged horizontally from front to back. The design of the chain structure realizes the orderly buffering of single rebars, and a permanent magnet is provided on the chain structure. The three buffer mechanisms are independent of each other, respectively corresponding to the classification buffering of the long bars of the web positioning net, the short bars of the web positioning net, and the short bars of the bottom plate positioning net 104, so as to realize the classification and grabbing use. At the same time, the setting of permanent magnets prevents the bars from slipping or misaligning during the transportation and buffering process, and ensures that the spacing of the bars is uniform.

[0022] The material conveying mechanism 3 is installed on the steel bar buffer mechanism 2 and is connected to the output port of the straightening and cutting mechanism 1 to convey the steel bars produced by the straightening and cutting mechanism 1 to the corresponding buffer mechanism. The material conveying mechanism 3 includes a steel bar conveying mechanism 31 disposed on three buffer mechanisms and connected to the output port of the straightening and cutting mechanism 1. The steel bar conveying mechanism 31 is provided with a pushing mechanism 32 corresponding to the three buffer mechanisms. The rebar conveying mechanism 31 is a conveying chain with a permanent magnet on its structure to receive the rebar fed by the straightening and cutting mechanism 1 and convey it horizontally to the feed end of the corresponding buffer mechanism. At the same time, the pushing direction of the pusher plate is perpendicular to the conveying direction of the rebar conveying mechanism 31, which can accurately push the rebar on the rebar conveying mechanism 31 to the chain of the corresponding buffer mechanism, complete the material distribution and buffering of rebar of different specifications, realize the automated buffering of raw materials, and improve the automation level of the production line.

[0023] The long rib extrusion mechanism 4 is located at the long rib processing station of the production line. It is used to receive long ribs from the steel bar buffer mechanism 2 and to bend and extrude the long ribs into shape. The long rib extrusion mechanism 4 is equipped with a receiving mechanism to receive long ribs from the long rib buffer mechanism 21 and transport the long ribs to the extrusion station of the long rib extrusion mechanism 4 to achieve precise bending and extrusion forming of the long ribs.

[0024] The steel mesh welding mechanism 5 is located at the first welding station of the production line and is used to weld the steel mesh. The steel mesh welding mechanism 5 includes a pallet movement track 51 and a resistance welding machine 52. The resistance welding machine 52 is located on the side of the pallet movement track 51, with the upper electrode of the resistance welding machine 52 located above the pallet movement track 51 and the lower electrode located below the pallet movement track 51. The welding current and welding time of the resistance welding machine 52 can be numerically controlled to adapt to different welding requirements, and the strength of the welded joint meets the requirements of the highway bridge construction specifications. A welding pallet body 53 is slidably mounted on the pallet motion track 51. The welding pallet body 53 can slide back and forth along the pallet motion track 51 via a servo drive system, moving back and forth between the steel bar loading station, the welding station, and the unloading station. A drive motor 531 is installed on the welding pallet body 53. The drive motor 531 is a servo motor, which drives the welding pallet body 53 to move precisely along the pallet movement track 51. A bracket movement guide rail 532 is installed on the welding pallet body 53. The bracket movement guide rail 532 is a high-precision linear guide rail, which is arranged parallel to the left and right sides of the welding pallet body 53. A stirrup positioning cylinder 533 is also installed on the welding pallet body 53. The extended end of the stirrup positioning cylinder 533 is equipped with a rebar positioning block, which can accurately limit the end of the rebar. A stirrup adjustment positioning bracket 534 is slidably mounted on the bracket motion guide rail 532, and a plurality of positioning net adjustment positioning brackets 535 are slidably mounted on the bracket motion guide rail 532. The plurality of positioning net adjustment positioning brackets 535 are located on the side of the stirrup adjustment positioning bracket 534 and are arranged sequentially along the length of the bracket motion guide rail 532. The stirrup adjustment positioning bracket 534 and the positioning net adjustment positioning bracket 535 are both driven by independent servo motors to slide along the bracket motion guide rail 532 to achieve distance adjustment. It should be noted that the spacing between the brackets can be precisely adjusted according to the steel bar spacing requirements of the box girder design drawings, adapting to the processing needs of positioning mesh of different beam types and sizes, without the need for manual adjustment of the bracket positions, which greatly improves production changeover efficiency. Both the welding tray body 53 and the stirrup spacing adjustment and positioning bracket 534 are equipped with stirrup positioning modules 536. The stirrup positioning modules 536 are equipped with clamping blocks, and the web stirrups 101 are clamped and positioned by the distance of the clamping blocks. This allows for the precise positioning of web stirrups 101 of different beam types and sizes, further improving welding accuracy and mesh forming quality.

[0025] The U-rib assembly and welding mechanism 6 is located at the second welding station of the production line and is used to realize the assembly and welding of U-ribs. The U-shaped rib assembly and welding mechanism 6 includes a U-shaped rib assembly platform 61 and a welding machine ground rail 62. The welding machine ground rail 62 is arranged parallel to the side of the U-shaped rib assembly platform 61. An assembly resistance welding machine 63 is slidably mounted on the welding machine ground rail 62. The welding part of the assembly resistance welding machine 63 can move to the top of the U-shaped rib assembly platform 61. The assembly resistance welding machine 63 is a mobile resistance welding machine. It can slide back and forth along the welding machine ground rail 62 through a servo drive system to automatically weld welding points at different positions on the U-shaped rib assembly platform 61 without the need for manual movement of the welding machine or workpiece, which greatly improves the assembly and welding efficiency. The U-shaped rebar assembly platform 61 is equipped with two bottom and web plate clamping cylinders 611. These cylinders are horizontal and have clamping blocks at their extended ends. They clamp and fix the web plate stirrups 101 and bottom plate stirrups 102 during assembly, preventing displacement or deformation of the stirrups during welding. The U-shaped rebar assembly platform 61 also has a bottom plate positioning rebar bracket 612 located between the two bottom and web plate clamping cylinders 611. This bracket supports the bottom plate positioning rebars, ensuring the relative positional accuracy of the bottom plate stirrups 102 and the bottom plate positioning short rebars 104. Finally, the U-shaped rebar assembly platform 61 has a bottom plate cylinder 613 located between the bottom plate positioning rebar brackets 612. This cylinder is used for axial positioning and clamping of the bottom plate positioning short rebars 104. The U-shaped reinforcement assembly platform 61 is also equipped with a bottom plate stirrup positioning slot 614 and a web plate forming stirrup positioning slot 615, which are used for the precise positioning of the bottom plate stirrup 102 and the web plate integrally formed stirrup. The position and spacing of the slot and positioning slot are preset according to the box girder design drawings to ensure that the dimensions of the assembled U-shaped reinforcement skeleton fully meet the design requirements.

[0026] The assembly U-rib buffer mechanism 7 is located in the second buffer area of ​​the production line and is used to buffer the assembly U-ribs. The assembly U-rib caching mechanism 7 is equipped with multiple independent caching stations to store the assembled U-rib skeleton in an orderly manner.

[0027] There are two hoppers 8, both located in the material storage area of ​​the production line, used to store the web plate stirrups 101 and the bottom plate stirrups 102. Each hopper 8 is equipped with an independent positioning slot, which can classify and store the prefabricated web plate stirrups 101 and bottom plate stirrups 102 in an orderly manner. Sensors are installed on the side of the hopper 8 to provide real-time feedback on the stock status of the stirrups in the hopper 8, so that operators can replenish the materials in a timely manner and ensure the continuous operation of the production line.

[0028] The feeding and discharging mechanism 9 is located above the first buffer area, the long rib processing station, the first welding station, the second welding station, the second buffer area, and the material storage area, and is used to realize the feeding, discharging, and transfer of various materials. The feeding and discharging mechanism 9 includes two gantry tracks 91, which are arranged in parallel on the production line. A first gantry 92, a second gantry 93, and a third gantry 94 are slidably arranged on the two gantry tracks 91 from left to right. The three gantry tracks are driven by independent servo drive systems to slide back and forth independently along the gantry tracks 91, so as to realize the precise picking, unloading, and transfer of materials at all stations of the production line. The first gantry 92 is equipped with a first gripper mechanism 95, the second gantry 93 is equipped with a second gripper mechanism 96, and the third gantry 94 is equipped with a third gripper mechanism 97. The three gripper mechanisms work together to complete the gripping and transfer of different processes and different types of workpieces. It should be noted that a corresponding servo drive system is also installed on the gantry, which allows the gripper mechanism to slide on the gantry. The servo drive system also includes a Z-axis lifting mechanism, and a rotating mechanism is set at the lower end of the Z-axis lifting mechanism. The gripper mechanism is located at the lower end of the rotating mechanism, thereby realizing the operation of the XYZ three axes and the four degrees of freedom of rotation. The first gripper mechanism 95 is used for gripping, transporting and feeding the positioning net long and short bars and web plate stirrups 101; the second gripper mechanism 96 is used for gripping, transporting and feeding the bottom plate stirrups 102 and bottom plate positioning short bars 104; and the third gripper mechanism 97 is used for gripping, transporting and feeding the web plate integrally formed stirrups and for gripping, transporting and discharging the assembled U-bars. The first gripper mechanism 95 includes a first gripper frame 951, a first servo module 952 is provided on the first gripper frame 951, and a first magnetic gripper 953 is provided on both the first gripper frame 951 and the first servo module 952. The first servo module 952 is a linear module used to adjust the distance between the magnetic grippers so that it can grip long ribs and stirrups with different spacing. The magnetic gripper located on the first gripper frame 951 is used to pick up the short reinforcement bars of the positioning net, and the magnetic gripper located on the first servo module 952 is used to pick up the long reinforcement bars of the positioning net and the web stirrups 101. The second gripper mechanism 96 includes a second gripper frame 961, a second magnetic gripper 962 is provided on the second gripper frame 961, a second servo module 963 is provided on the second gripper frame 961, and a first cylinder gripper 964 is provided on both the second gripper frame 961 and the second servo module 963. The second magnetic gripper 962 is used to pick up the bottom plate positioning steel bars, and the first cylinder gripper 964 is used to grab the bottom plate stirrups. At the same time, the distance of the first cylinder gripper 964 is adjusted by the second servo module 963 so that it can grab bottom plate stirrups 102 of different sizes. The third gripper mechanism 97 includes a third gripper frame 971, a third magnetic gripper 972 is provided on the third gripper frame 971, a third servo module 973 is provided on the third gripper frame 971, a second cylinder gripper 974 is provided on both the third gripper frame 971 and the third servo module 973, and a slot is provided on the third magnetic gripper 972. The third servo module 973 is used to adjust the distance between the magnetic gripper slots to accommodate web stirrups 101 of different sizes; It should be noted that the magnetic gripper uses electrically controlled magnetic attraction, which retains the magnetism when the power is off and demagnetizes when the power is on, and can stably attract steel bars of different diameters and lengths.

[0029] Furthermore, the entire production line is equipped with a central control system, which has a built-in PLC controller and an industrial touch screen. The straightening and cutting mechanism 1, the rebar buffer mechanism 2, the material conveying mechanism 3, the long bar extrusion mechanism 4, the rebar mesh welding mechanism 5, the U-bar assembly and welding mechanism 6, and the feeding and discharging mechanism 9 are all electrically connected to the central control system. Operators can preset production parameters and select box girder types through the touch screen, and the production line can complete the entire process of automated production. At the same time, it can monitor the operating status of each mechanism, production count, equipment failure and other information in real time, so as to realize the intelligent management and control of the production line.

[0030] Through the above structural setup, the entire production line is designed to integrate the standardized processing of positioning steel mesh for precast box girders and cast-in-place box girders and the assembly and forming of stirrups. It can complete the entire automated production process of straightening and cutting, buffering and conveying, bending and forming, mesh welding and stirrup assembly welding of positioning steel bars for the bottom web of box girders in one stop. It completely replaces the traditional manual on-site binding and positioning operation mode, and fundamentally solves the industry pain points of poor positioning accuracy, large labor input and unstable product quality of manual installation of prestressed tendons.

[0031] A method for producing precast beam composite U-shaped reinforcement, the method is as follows: S1. The straightening and cutting mechanism 1 is used to straighten and cut the long ribs of the web positioning mesh, the short ribs of the web positioning mesh, and the short ribs of the bottom plate positioning mesh 104 respectively. S2. Then, the web positioning mesh long bars, web positioning mesh short bars, and bottom plate positioning short bars 104 obtained from the production are transported to the corresponding steel bar buffering mechanism 2 for buffering through the material conveying mechanism 3. S3. The long ribs of the web positioning mesh on the long rib buffer mechanism 21 are grasped by the long rib extrusion mechanism 4 and processed to achieve extrusion molding. S4. The long and short reinforcing bars of the web positioning mesh are gripped separately by the first gripper mechanism 95 on the first gantry 92 and transported to the welding tray body 53. S5. The welding tray body 53 is moved to the resistance welding machine 52 to weld the long and short ribs. After the welding is completed, the web positioning mesh 103 is obtained, and the welding tray body 53 carries the welded web positioning mesh 103 back to its original position. S6. Then, the second gripper mechanism 95 on the first gantry 92 grabs the web plate stirrups 101 in the hopper 8 and onto the welding pallet body 53. S7. The welding tray body 53 is moved to the resistance welding machine 52 again for welding to obtain the web plate integrally formed stirrup. S8. Then, the web plate integrally formed stirrups are grabbed and transported to the U-shaped reinforcement assembly platform 61 by the third gripper mechanism 97 on the third gantry 94. The second gripper mechanism 96 on the second gantry 93 grabs the bottom plate stirrups 102 and the bottom plate positioning short bars 104 and transports them to the U-shaped reinforcement assembly platform 61. S9. The assembly resistance welding machine 63 assembles and welds the web plate integrally formed stirrups, bottom plate stirrups 102 and bottom plate positioning short bars 104 on the U-bar assembly platform 61 to obtain the assembled U-bar. S10. The assembly U-shaped reinforcement is grabbed by the third gripper mechanism 97 on the third gantry 94 and transported to the assembly U-shaped reinforcement buffer mechanism 7 for buffering.

[0032] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0033] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0034] Additionally, "multiple" refers to two or more.

[0035] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A precast beam composite U-shaped reinforcement, characterized in that, include: U-shaped main body (10), the U-shaped main body (10) includes web stirrups (101) and bottom plate stirrups (102), the number of web stirrups (101) is two and they are arranged symmetrically and obliquely, and the bottom plate stirrups (102) are arranged on the two web stirrups (101); The positioning steel mesh includes a web positioning mesh (103) and a bottom plate positioning short bar (104). The web positioning mesh (103) is welded to the web stirrups (101), and the bottom plate positioning short bar (104) is welded to the bottom plate stirrups (102).

2. A production line for precast beam composite U-shaped reinforcement, used for the precast beam composite U-shaped reinforcement as described in claim 1, characterized in that, include: The straightening and cutting mechanism (1) is located at the front end of the production line and is used to straighten and cut the long ribs of the web positioning mesh, the short ribs of the web positioning mesh, and the short ribs of the bottom plate positioning mesh (104). The steel bar buffer mechanism (2) is located in the first buffer area of ​​the production line and is used to buffer the long bars of the web positioning mesh, the short bars of the web positioning mesh, and the short bars of the bottom plate positioning mesh (104). The material conveying mechanism (3) is set on the steel bar buffer mechanism (2) and connected to the output port of the straightening and cutting mechanism (1) to convey the steel bars produced by the straightening and cutting mechanism (1) to the corresponding buffer mechanism. Long rib extrusion mechanism (4), the long rib extrusion mechanism (4) is located at the long rib processing station of the production line, and is used to receive long ribs from the steel bar buffer mechanism (2) and bend and extrude the long ribs into shape; The steel mesh welding mechanism (5) is located at the first welding station of the production line and is used to realize the welding of steel mesh. The U-shaped rib assembly and welding mechanism (6) is located at the second welding station of the production line and is used to realize the assembly and welding of U-shaped ribs. The assembly U-rib buffer mechanism (7) is located in the second buffer area of ​​the production line and is used to buffer the assembly U-ribs; The number of the material bins (8) is two, and both are located in the material storage area of ​​the production line, for storing the web plate stirrups and the bottom plate stirrups; The feeding and discharging mechanism (9) is located above the first buffer area, the long rib processing station, the first welding station, the second welding station, the second buffer area and the material storage area, and is used to realize the feeding, discharging and transfer of various materials.

3. The production line for precast beam composite U-shaped reinforcement according to claim 2, characterized in that: The rebar buffer mechanism (2) includes a long rebar buffer mechanism (21), a web short rebar buffer mechanism (22), and a bottom plate rebar buffer mechanism (23) arranged sequentially from left to right. The long rebar buffer mechanism (21) is a horizontally arranged chain structure with a permanent magnet on it. The web short rebar buffer mechanism (22) and the bottom plate rebar buffer mechanism (23) are both horizontally arranged chain structures with a permanent magnet on them.

4. The production line for precast beam composite U-shaped reinforcement according to claim 2, characterized in that: The material conveying mechanism (3) includes a steel bar conveying mechanism (31) disposed on three buffer mechanisms and connected to the output port of the straightening and cutting mechanism (1). The steel bar conveying mechanism (31) is provided with a pushing mechanism (32) corresponding to the three buffer mechanisms. The steel bar conveying mechanism (31) is a conveying chain, and a permanent magnet is provided on the chain structure.

5. The production line for precast beam composite U-shaped reinforcement according to claim 2, characterized in that: The steel mesh welding mechanism (5) includes a pallet movement track (51) and a resistance welding machine (52). The resistance welding machine (52) is located on the side of the pallet movement track (51), and the upper electrode of the resistance welding machine (52) is located above the pallet movement track (51), and the lower electrode is located below the pallet movement track (51). A welding pallet body (53) is provided on the pallet movement track (51), and the welding pallet body (53) moves along the pallet movement track (51).

6. The production line for precast beam composite U-shaped reinforcement according to claim 5, characterized in that: The welding pallet body (53) is provided with a drive motor (531), the welding pallet body (53) is provided with a bracket movement guide rail (532), and the welding pallet body (53) is also provided with a stirrup positioning cylinder (533). A stirrup adjustment positioning bracket (534) is slidably arranged on the bracket movement guide rail (532), and a plurality of positioning net adjustment positioning brackets (535) are slidably arranged on the bracket movement guide rail (532), with the plurality of positioning net adjustment positioning brackets (535) located on the side of the stirrup adjustment positioning bracket (534). Both the welding tray body (53) and the stirrup spacing adjustment and positioning bracket (534) are equipped with stirrup positioning modules (536).

7. The production line for precast beam composite U-shaped reinforcement according to claim 2, characterized in that: The U-rib assembly welding mechanism (6) includes a U-rib assembly platform (61) and a welding machine ground rail (62). The welding machine ground rail (62) is located on the side of the U-rib assembly platform (61). An assembly resistance welding machine (63) is slidably mounted on the welding machine ground rail (62). The welding part of the assembly resistance welding machine (63) can move to above the U-rib assembly platform (61). The U-shaped rebar assembly platform (61) is equipped with two bottom web plate clamping cylinders (611), the U-shaped rebar assembly platform (61) is equipped with a bottom plate positioning rebar bracket (612) located between the two bottom web plate clamping cylinders (611), and the U-shaped rebar assembly platform (61) is equipped with a bottom plate cylinder (613) located between the bottom plate positioning rebar brackets (612). The U-shaped reinforcement assembly platform (61) is also provided with a bottom plate stirrup positioning slot (614) and a web plate forming stirrup positioning slot (615).

8. The production line for precast beam composite U-shaped reinforcement according to claim 1, characterized in that: The feeding and discharging mechanism (9) includes two gantry tracks (91). A first gantry (92), a second gantry (93), and a third gantry (94) are slidably arranged on the two gantry tracks (91) from left to right. A first gripper mechanism (95) is provided on the first gantry (92), a second gripper mechanism (96) is provided on the second gantry (93), and a third gripper mechanism (97) is provided on each of the third gantry (94).

9. The production line for precast beam composite U-shaped reinforcement according to claim 8, characterized in that: The first gripper mechanism (95) includes a first gripper frame (951), a first servo module (952) is provided on the first gripper frame (951), and a first magnetic gripper (953) is provided on both the first gripper frame (951) and the first servo module (952). The second gripper mechanism (96) includes a second gripper frame (961), a second magnetic gripper (962) is provided on the second gripper frame (961), a second servo module (963) is provided on the second gripper frame (961), and a first cylinder gripper (964) is provided on both the second gripper frame (961) and the second servo module (963). The third gripper mechanism (97) includes a third gripper frame (971), a third magnetic gripper (972) is provided on the third gripper frame (971), a third servo module (973) is provided on the third gripper frame (971), and a second cylinder gripper (974) is provided on both the third gripper frame (971) and the third servo module (973).

10. A method for producing precast beam composite U-shaped reinforcement, based on the production line for precast beam composite U-shaped reinforcement according to any one of claims 2-9, characterized in that: The methods include the following: S1. The straightening and cutting of the web positioning mesh long ribs, web positioning mesh short ribs, and bottom plate positioning short ribs (104) are completed by the straightening and cutting mechanism (1); S2. Then, the web positioning mesh long bars, web positioning mesh short bars, and bottom plate positioning short bars (104) obtained from the production are transported to the corresponding steel bar buffering mechanism (2) for buffering through the material conveying mechanism (3); S3. The long ribs of the web positioning mesh on the long rib buffer mechanism (21) are grabbed by the long rib extrusion mechanism (4) and processed to achieve extrusion molding; S4. The long and short reinforcing bars of the web positioning mesh are gripped separately by the first gripper mechanism (95) on the first gantry (92) and transported to the welding tray body (53). S5. The welding tray body (53) is moved to the resistance welding machine (52) to weld the long and short ribs. After the welding is completed, the web positioning mesh (103) is obtained, and the welding tray body (53) carries the welded web positioning mesh (103) back to its original position. S6. Then, the second gripper mechanism (95) on the first gantry (92) grabs the web plate stirrups (101) in the hopper (8) and transfers them to the welding pallet body (53); S7. The welding tray body (53) is moved to the resistance welding machine (52) again for welding to obtain the web plate integrally formed stirrup; S8. Then, the web plate integrally formed stirrups are grabbed and transported to the U-bar assembly platform (61) by the third gripper mechanism (97) on the third gantry (94). The second gripper mechanism (96) on the second gantry (93) grabs the bottom plate stirrups (102) and the bottom plate positioning short bars (104) and transports them to the U-bar assembly platform (61). S9. The assembly resistance welding machine (63) assembles and welds the web plate integrally formed stirrups, bottom plate stirrups (102) and bottom plate positioning short bars (104) on the U-bar assembly platform (61) to obtain the assembly U-bar. S10. The assembly U-rib is grabbed by the third gripper mechanism (97) on the third gantry (94) and transported to the assembly U-rib buffer mechanism (7) for buffering.

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