Intelligent steel sawing, threading, bending and bending arc one-drag-four production line

Abstract

The present application relates to the technical field of steel bar processing, and particularly to an intelligent steel bar sawing, sleeving, bending and bending production line, and a processing method thereof, which comprises the following steps: original material paving, specification identification and shunting; each specification steel bar is cut to size; the steel bars are distributed according to the requirements of each downstream work station; the steel bars distributed to the temporary storage area of the sleeving work station are sleeved; the sleeved steel bars are stored in the sleeving finished product storage area; the steel bars distributed to the temporary storage area of the anchor rod work station are processed into anchor rods; the processed anchor rods are stored in the anchor rod finished product storage area; the steel bars are bent into arcs; the steel bars are bent into bundles; the bent steel bars are transferred to the downstream work station after being flipped and connected; the finished steel bars are classified and stored, and the excess material is recycled. The present application improves the consistency of products processed by multiple work stations through cross-process linkage compensation. The end face quality detection results of the sawing work station are transmitted to the downstream work stations such as sleeving, anchor rod, bending arc and horizontal bending, and each downstream work station adjusts the processing position according to the end face deviation data.

Description

Technical Field

[0001] This invention relates to the field of rebar processing technology, and in particular to an intelligent rebar sawing, threading, bending, and arc-bending production line with four separate lines. Background Technology

[0002] Steel reinforcement is the most widely used structural material in construction engineering, and its processing precision and quality directly affect the safety and durability of concrete structures. With the rapid development of large-scale projects such as high-speed rail, water conservancy and hydropower, and nuclear power, steel reinforcement processing is shifting from traditional decentralized single-machine operation to centralized, automated, and intelligent production line models.

[0003] Integrating multiple processes such as sawing, wire drawing, bending, and arc bending into a single physical production line, achieving a seamless process from raw material entry to finished product palletizing, has become an inevitable direction for technological upgrading in the industry.

[0004] Currently, the industry mainly adopts three technical routes: First, single-machine decentralized processing, where sawing, threading, bending, and arc bending are completed by independent single machines, and manual transfer is relied upon between processes; second, serial automated lines, where multiple machines are connected in series via roller conveyors, and steel bars flow through each process in a fixed order; and third, modular flexible production lines, where each processing unit adopts a modular design and can be flexibly combined and arranged according to site conditions, but the overall flow is still a single linear flow mode.

[0005] In existing technologies, serial production lines adopt a single-flow layout, with one production line corresponding to one product processing path. When a certain workstation experiences a shortage of materials or a malfunction, the entire line is forced to stop and wait, resulting in low overall equipment utilization and difficulty in adapting to the processing needs of multiple varieties and small batches. At the same time, there is a lack of real-time linkage and scheduling mechanism between the upstream sawing process and the downstream processing workstations. The processing rhythm of each workstation varies greatly, and there is a contradiction between the fixed rhythm of upstream material supply and the dynamic demand of downstream, which can easily lead to material blockage or material shortage in the intermediate storage area.

[0006] In addition, during the roller conveyor process, the 3-12m long steel bars are prone to deflection and sagging due to their own weight, and there is also a lateral deviation during the conveying process, which leads to centering deviation when entering the threading or bending station, affecting the quality of thread processing and the accuracy of bending.

[0007] Furthermore, the end face perpendicularity deviation and burrs generated during the sawing process were not effectively detected and compensated for, directly transmitting to subsequent threading and bending processes, resulting in poor thread engagement and misalignment of the bending point. Simultaneously, the elastic rebound after bending is affected by batch variations in rebar diameter and yield strength, leading to large fluctuations in the rebound angle. Existing methods rely on manual trial bending adjustments, resulting in poor accuracy and stability.

[0008] In addition, when steel bars of various diameters share the same feeding and conveying line, the lack of an automatic identification and diversion mechanism can easily lead to the problem of mixed materials being sent to the wrong workstation.

[0009] Based on this, we designed an intelligent steel bar production line with multi-station parallel material supply and multi-process linkage scheduling, as well as its processing method, which has significant engineering application value. Summary of the Invention

[0010] To solve one of the aforementioned technical problems, the present invention employs a four-phase intelligent rebar sawing, threading, bending, and arc-bending production line. The specific processing method of this production line during operation includes the following steps:

[0011] The first step is to complete the laying out, specification identification, and sorting of raw materials;

[0012] Bundles of steel bars are hoisted to the vibrating and leveling station, where they are vibrated to spread evenly along the width. The leveled steel bars are then lifted one by one and conveyed forward. During the conveying process, the diameter of the steel bars is checked, and steel bars of different diameters are diverted to the corresponding conveying channels according to the test results.

[0013] The second step is to cut the steel bars of various specifications after they have been diverted to the required length.

[0014] Steel bars of various specifications are cut to the specified length according to the production schedule; the end face of the cut steel bars is inspected for perpendicularity deviation and burr height.

[0015] The third step is to distribute the cut steel bars to downstream workstations according to their needs.

[0016] After being cut to length, the steel bars enter the conveyor line. During the conveying process, the long steel bars are supported and automatically centered. The storage status of each downstream processing station and the remaining processing time of the currently being processed task are collected in real time. The conveying path is dynamically adjusted according to the storage threshold and remaining processing time of each station, and the steel bars are allocated to the temporary storage area of ​​the corresponding processing station. The end face inspection results are sent to each downstream processing station simultaneously.

[0017] The fourth step involves transferring the reinforcing bars allocated to the temporary storage area of ​​the threading station to complete the threading process after horizontal translation and flipping. The threaded reinforcing bars are then stored in the finished threading storage area.

[0018] The fifth step involves transferring the steel bars allocated to the temporary storage area of ​​the anchor bolt processing station after lateral translation and flipping to complete the anchor bolt processing; the steel bars after the anchor bolt processing is completed are then stored in the finished anchor bolt storage area.

[0019] The sixth step involves transporting the steel bars that need to be bent along two paths to complete the bending process.

[0020] After threading, the steel bars are transported from the threaded finished product storage area to the bending processing station. Steel bars that do not require threading are distributed to the temporary storage area of ​​the bending processing station via the conveying and diversion station. The bending is completed according to the set bending radius and bending angle, and the formed steel bars are stored in the bending finished product storage area.

[0021] Step 7: The steel bars allocated to the temporary storage area of ​​the horizontal bending station are bundled and bent into shape; after bending, the steel bars are turned over and transferred to the unloading station.

[0022] The eighth step is to classify and store the finished steel bars processed at each workstation, and to complete the recycling of surplus materials;

[0023] The steel bars in each finished product storage area are diverted to the corresponding finished product storage area according to specifications; short pieces generated during the sawing process are detected in length, and those shorter than the set length threshold are moved to the surplus material collection area.

[0024] Preferably, in the first step, after the bundled steel bars are hoisted to the vibratory laying station, the vibration frequency is 20-50Hz and the vibration time is 10-30 seconds, so that the bundled steel bars are evenly laid along the width direction, and the thickness of the steel bar layer after laying does not exceed 300mm; the laid steel bars are lifted one by one, with a lifting interval of 500-1000mm, and then conveyed forward; during the conveying process, the diameter of the steel bars is detected, and the diameter measurement method is (using a photoelectric diameter gauge, two sets of photoelectric probes can be symmetrically arranged along the radial direction of the steel bars as needed, with a detection range of φ12-φ40mm), and steel bars of different diameter specifications are diverted to the corresponding conveying channels according to the detection results, with a diversion accuracy of ±0.5mm.

[0025] Preferably, in the second step, the steel bars of each specification are cut to the specified length according to the production schedule. The specified length ranges from 3 to 12 meters, and the specified length accuracy is ±1mm. After cutting, the end face of the steel bar is inspected for perpendicularity deviation and burr height. The threshold for perpendicularity deviation is 0.5mm, and the threshold for burr height is 1.0mm. When the perpendicularity deviation or burr height exceeds the threshold, the steel bar is diverted to the rework station and enters the next process after the end face is processed to meet the requirements.

[0026] Preferably, in the third step, the cut steel bars enter the conveying line at a speed of 5-15 m / min; during the conveying process, the long steel bars are supported by a follow-up support, which is arranged at intervals along the conveying direction at a distance of 2-5 meters, with a lifting stroke of 200-500 mm. When the follow-up support is used, the material support surface and the bottom surface of the steel bar are kept at a gap of 10-30 mm; and automatic centering is performed, with the centering method being (centering on both sides, which is automatically adjusted according to the diameter of the steel bar), and the centering accuracy being ±2 mm.

[0027] Preferably, in the third step, the storage status of each downstream processing station and the remaining processing time of the currently being processed are collected in real time, and the conveying path is dynamically adjusted according to priority rules based on the storage threshold of each station and the remaining processing time.

[0028] The priority rule is as follows: when the material storage level of a downstream workstation is lower than the set lower limit, or when the remaining processing time of the currently being processed task exceeds the set threshold, the priority of that workstation is increased, and steel bars are preferentially allocated to that workstation.

[0029] When the material storage level of a downstream workstation is higher than the set upper limit, the priority of that workstation is reduced and the allocation of steel bars to that workstation is suspended. The material storage level threshold is divided into three levels: low alarm threshold, medium normal threshold, and high full material threshold.

[0030] Preferably, in the fourth step, the steel bars allocated to the temporary storage area of ​​the threading processing station are transferred to complete the threading process after lateral translation and flipping; the lateral translation is carried out by (truss robot translation, translation speed is 0.5~2m / s, translation stroke is 1~3 meters), and the flipping is carried out by (pneumatic flipping, flipping angle is 180°, flipping time is 2~5 seconds); the threading processing time is 30~40 seconds / piece, and the threading length is 50~100mm; the steel bars after threading are stored in the finished threading storage area, which is a two-level silo structure, and each silo can store 2~5 tons of steel bars.

[0031] Preferably, in the fifth step, the steel bars allocated to the temporary storage area of ​​the anchor bolt processing station are transferred to complete the anchor bolt processing after being horizontally moved and flipped; the anchor bolt processing can be a single-head processing and grinding process of 3 to 12 meters, and the double-headed ones can be processed and stored separately; the steel bars after the anchor bolt processing is completed are stored in the finished anchor bolt storage area, which is a three-level silo structure, and each silo can store 2 to 5 tons of steel bars.

[0032] Preferably, in the sixth step, the threaded steel bars are conveyed from the threaded finished product storage area to the bending processing station at a conveying speed of 3 to 10 m / min; the steel bars that do not require threading are distributed to the temporary storage area of ​​the bending processing station via the conveying and diversion station; the bending is completed according to the set bending radius and bending angle, with the bending angle ranging from 1 to 5°; the bending speed is 5 to 15 m / min; and the formed steel bars are stored in the bending finished product storage area.

[0033] Preferably, in the seventh step, the steel bars allocated to the temporary storage area of ​​the horizontal bending station are bundled and bent into shape; the number of bundles is: 3-4 φ16 steel bars and 4-5 φ12 steel bars; after bending, the steel bars are turned over and transferred to the unloading station. The turning is carried out by cylinder-driven turning, with a turning angle of 90° and a turning time of 3-8 seconds; the unloading station can be equipped with an industrial robot or a gantry robot to complete the finished product stacking.

[0034] Preferably, in the eighth step, the steel bars in each finished product storage area are diverted to the corresponding finished product storage area according to their specifications. The sorting method is (sorting according to the diameter and length of the steel bars, with steel bars of different specifications stored in different finished product storage areas); the short material generated during the sawing process is detected in length, and short material with a length less than the set length threshold is moved to the surplus material collection area. The short material length threshold is 300mm.

[0035] Preferably, the method further includes an intelligent scheduling and control step: the processing tasks of each workstation are uniformly scheduled through the existing MES production system, the processing status, storage status and equipment operation status of each workstation are collected in real time, and the processing sequence and processing rhythm of each workstation are dynamically adjusted according to the production plan to achieve simultaneous operation of each workstation.

[0036] Preferably, after detecting the diameter of the reinforcing bar in the first step, the diameter specification information is simultaneously sent to each downstream processing station, and each processing station automatically adjusts the processing parameters according to the diameter specification of the reinforcing bar.

[0037] For example, the threading station automatically adjusts the spacing between the thread rolling wheels and the threading speed according to the diameter of the rebar, and the bending station automatically adjusts the bending radius compensation amount according to the diameter of the rebar.

[0038] Preferably, after detecting the end face perpendicularity deviation and burr height in the second step, the end face quality information is simultaneously sent to each downstream processing station; the threading processing station automatically adjusts the bar clamping position according to the end face perpendicularity deviation, and the bending processing station automatically adjusts the bending start position according to the end face perpendicularity deviation.

[0039] The method also includes data acquisition and remote monitoring steps: multi-dimensional automatic data acquisition is achieved through the existing production management system, and the acquired content includes the processing quantity, processing time, equipment operating status, and fault alarm information of each workstation.

[0040] The present invention also provides an intelligent steel bar sawing, threading, bending and arc bending production line with four stations, which specifically includes a material feeding and sorting station, a sawing station, a conveying and diverting station, a threading processing station, an anchor processing station, an arc bending processing station, a horizontal bending station and a sorting station arranged in sequence according to the processing flow.

[0041] The material feeding and distributing station sequentially completes the steps of vibrating and laying the steel bars, lifting and conveying them, and measuring and distributing them.

[0042] The sawing station sequentially completes the steps of fixed-length conveying, sawing and cutting, and end face inspection.

[0043] The conveying and diversion station completes the long material follow-up support, guide and center, and dynamically allocates the conveying path steps according to the needs of the downstream station.

[0044] The threading processing station sequentially completes the steps of lateral transfer, flipping, thread rolling, and temporary storage of the finished threaded product.

[0045] The anchor bolt processing station sequentially completes the steps of lateral transfer, flipping, anchor bolt processing, and temporary storage of finished anchor bolts.

[0046] The bending processing station completes the steps of bending and forming and temporary storage of finished bending products.

[0047] The horizontal bending station sequentially completes the steps of bundle bending, material turning and unloading and transfer.

[0048] The sorting station completes the steps of classifying and storing finished products and recycling short and surplus materials.

[0049] The discharge end of the feeding and distributing station is arranged opposite to the feed end of the sawing station, and the discharge end of the sawing station is arranged opposite to the feed end of the conveying and diverting station.

[0050] The first discharge end of the conveying and diverting station is arranged opposite to the feed end of the threading processing station; the second discharge end of the conveying and diverting station is arranged opposite to the feed end of the anchor bolt processing station; the third discharge end of the conveying and diverting station is arranged opposite to the feed end of the bending processing station; and the fourth discharge end of the conveying and diverting station is arranged opposite to the feed end of the horizontal bending station.

[0051] The discharge ends of the threading station, the anchor bolt processing station, the arc bending station, and the horizontal bending station are respectively arranged opposite to the feed end of the sorting station.

[0052] The four discharge ends of the conveying and diversion station correspond to the four downstream stations respectively. It is not a simple mechanical diversion of one to four, but a one-to-four diversion with dynamic scheduling. The storage position of each downstream station is monitored in real time, and the material is sent to the branch line where it is needed, so as to achieve self-balancing of the cycle time of the multi-station.

[0053] The discharge end of the threading station is connected to the feed end of the bending station, realizing direct conveying of the bending after threading: the discharge end of the threading station is directly connected to the feed end of the bending station, and the threaded steel bars are directly sent to the bending station, shortening the logistics path of bending after threading.

[0054] The eight workstations are arranged sequentially according to the processing flow, rather than being scattered: the materials are arranged sequentially according to the processing flow, and the materials flow directly between the workstations, reducing transfer links and transfer time.

[0055] The material feeding and sorting station is connected to the sawing station, and the sawing station is connected to the conveying and diversion station via conveyor lines. This solution uses direct conveyor line connections, allowing materials to flow automatically between stations and reducing transfer steps.

[0056] The conveying and diversion station is connected to the threading station and the anchor bolt processing station via lateral transfer.

[0057] The material conveying and diversion station is connected to the threading and anchoring stations via lateral transfer, not longitudinal transfer. In this solution, the threading and anchoring stations are located to the side of the conveying and diversion station and are connected via lateral transfer, shortening the material conveying path.

[0058] The lateral transfer connects two downstream workstations, realizing two branches in a one-to-four system. This solution features lateral branching, resulting in a more compact layout.

[0059] The conveying and diversion station is connected to the bending and arc processing station and the horizontal bending station via conveyor lines.

[0060] The conveyor branching station is connected to the bending and horizontal bending stations via a conveyor line, realizing the other two branches of the one-to-four system. The conventional approach is that the bending and horizontal bending stations are fed independently, but this solution directly feeds materials from the conveyor branching station through the conveyor line, realizing one sawing unit supplying materials to four downstream stations.

[0061] The discharge end of the threading station is connected to the feed end of the bending station, and the threaded steel bars are transported to the bending station through the finished threading storage area.

[0062] This solution uses a conveyor line for direct connection, allowing threaded steel bars to be directly sent for bending, thus shortening the logistics path.

[0063] After threading, the reinforcing bars are conveyed through the finished threading storage area, rather than being directly fed from the threading machine to the bending area. The finished threading storage area acts as a buffer, and the cycles of threading and bending do not need to be strictly synchronized, thus decoupling the cycles of the two stations.

[0064] The discharge ends of the four downstream processing stations are respectively connected to the inlet ends of the sorting stations, and the finished steel bars are collected and transported to the sorting stations.

[0065] The outputs from the four downstream stations are all collected at the sorting station, achieving unified sorting; the finished products from the four stations are all collected at the sorting station, automatically sorted and classified for storage, reducing manual sorting steps.

[0066] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0067] 1. This invention improves product consistency through cross-process linkage compensation in multi-station parallel processing. This solution synchronously transmits the end-face quality inspection results from the sawing station to downstream processing stations such as threading, anchor bolting, bending, and horizontal bending. Each downstream station pre-adjusts its processing positioning based on the end-face deviation data.

[0068] Compared to existing technologies where each process is independently aligned and end-face errors are cumulatively passed downstream, this solution uses upstream detection data to drive downstream pre-compensation. This eliminates the impact of end-face deviations on subsequent processing accuracy at the source of the process chain, significantly reducing the dispersion of processing accuracy for different specifications of steel bars in the same batch and effectively ensuring product consistency.

[0069] 2. The present invention improves the continuous operation capability of a one-to-four production line by combining long material follow-up support and dynamic scheduling. In this solution, long steel bars are followed up by spaced, liftable material support devices at the conveying and diversion stations. At the same time, a dynamic priority scheduling strategy based on three-level storage level thresholds is used to adjust the material supply sequence of each downstream station in real time.

[0070] Compared to existing technologies where fixed material support frames cause frictional obstruction during conveying and production schedule conflicts between workstations due to fixed order, this solution eliminates the deviation of long material conveying through soft contact follow-up support. At the same time, it achieves self-balancing of the cycle time of each workstation through hunger-driven scheduling logic, enabling the entire production line to maintain continuous and stable operation under mixed production conditions of multiple specifications.

[0071] 3. The upstream specification identification of this invention enables rapid changeover in multi-specification mixed-line production by synchronously identifying upstream specifications across workstations. After the rebar diameter is detected at the material loading and sorting station, the diameter specification information is synchronously sent to each downstream processing station, and each station automatically adjusts its processing parameters based on the specification information.

[0072] Compared to existing technologies that require manual parameter adjustments at each workstation and involve long downtime when changing specifications, this solution eliminates redundant testing and manual adjustment steps through a specification information transmission mechanism that uses one upstream test and shares downstream. This allows for production lines to switch between different specifications without downtime, significantly improving the production line's responsiveness to different product specifications.

[0073] 4. The dual-line integrated bending layout and bundled bending process of this invention improve the processing output per unit space. This solution merges the two paths of bending after threading and bending without threading into the same bending processing station, and adopts a bundled bending processing method in the horizontal bending station.

[0074] Compared to existing technologies where the wire thread and bending wire are arranged independently, and horizontal bending machines process single strands, this solution reduces the redundant configuration of bending equipment by combining the two lines into one, and increases the processing capacity per unit time of a single station by bending in bundles. This effectively improves the overall processing output capacity of the entire production line under the same floor space conditions. Attached Figure Description

[0075] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the accompanying drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. In all the drawings, similar elements or components are generally identified by similar reference numerals. In the drawings, the elements or components are not necessarily drawn to scale.

[0076] Figure 1 This is a flowchart of the processing technology of the present invention.

[0077] Figure 2 This is a block diagram showing the layout and connection of the production line of the present invention.

[0078] Figure 3 This is a layout diagram of the present invention.

[0079] In the diagram, 1 is the material feeding and sorting station; 2 is the sawing station; 3 is the conveying and diversion station; 4 is the threading station; 5 is the anchor bolt processing station; 6 is the bending station; 7 is the horizontal bending station; and 8 is the sorting station. Detailed Implementation

[0080] The embodiments of the technical solution of the present invention will now be described in detail with reference to the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and are therefore merely examples and should not be used to limit the scope of protection of the present invention. The specific structure of the present invention is as follows: Figures 1-3 As shown in the image.

[0081] The intelligent rebar sawing, threading, bending, and arc-bending production line has the following specific processing steps during operation:

[0082] The first step is to complete the laying out, specification identification, and sorting of raw materials;

[0083] Bundles of steel bars are hoisted to the vibrating and leveling station, where they are vibrated to spread evenly along the width. The leveled steel bars are then lifted one by one and conveyed forward. During the conveying process, the diameter of the steel bars is checked, and steel bars of different diameters are diverted to the corresponding conveying channels according to the test results.

[0084] The second step is to cut the steel bars of various specifications after they have been diverted to the required length.

[0085] Steel bars of various specifications are cut to the specified length according to the production schedule; the end face of the cut steel bars is inspected for perpendicularity deviation and burr height.

[0086] The third step is to distribute the cut steel bars to downstream workstations according to their needs.

[0087] After being cut to length, the steel bars enter the conveyor line. During the conveying process, the long steel bars are supported and automatically centered. The storage status of each downstream processing station and the remaining processing time of the currently being processed task are collected in real time. The conveying path is dynamically adjusted according to the storage threshold and remaining processing time of each station, and the steel bars are allocated to the temporary storage area of ​​the corresponding processing station. The end face inspection results are sent to each downstream processing station simultaneously.

[0088] The fourth step involves transferring the reinforcing bars allocated to the temporary storage area of ​​the threading station to complete the threading process after horizontal translation and flipping. The threaded reinforcing bars are then stored in the finished threading storage area.

[0089] The fifth step involves transferring the steel bars allocated to the temporary storage area of ​​the anchor bolt processing station after lateral translation and flipping to complete the anchor bolt processing; the steel bars after the anchor bolt processing is completed are then stored in the finished anchor bolt storage area.

[0090] The sixth step involves transporting the steel bars that need to be bent along two paths to complete the bending process.

[0091] After threading, the steel bars are transported from the threaded finished product storage area to the bending processing station. Steel bars that do not require threading are distributed to the temporary storage area of ​​the bending processing station via the conveying and diversion station. The bending is completed according to the set bending radius and bending angle, and the formed steel bars are stored in the bending finished product storage area.

[0092] Step 7: The steel bars allocated to the temporary storage area of ​​the horizontal bending station are bundled and bent into shape; after bending, the steel bars are turned over and transferred to the unloading station.

[0093] The eighth step is to classify and store the finished steel bars processed at each workstation, and to complete the recycling of surplus materials;

[0094] The steel bars in each finished product storage area are diverted to the corresponding finished product storage area according to specifications; short pieces generated during the sawing process are detected in length, and those shorter than the set length threshold are moved to the surplus material collection area.

[0095] This technical solution differs from the decentralized model of independent material feeding and sawing in conventional production lines. This solution dynamically distributes the sawn steel bars according to the needs of each downstream workstation through a conveyor diversion station, changing the traditional layout logic of multiple sawing and multiple material feeding.

[0096] The scheduling for parallel material supply to four workstations (one main unit and four substations) is not based on the order of processing tasks, but rather on the real-time demand of each workstation. Conventional production lines schedule materials in a sequential manner, either processing tasks first and then those last, or rotating material supply according to workstation order. This fixed-sequence scheduling inevitably leads to rhythm conflicts when the processing paces of different workstations are inconsistent. This solution uses a different scheduling logic: it monitors the material storage capacity of each workstation and the remaining processing time of the currently processing task in real time. It prioritizes supplying materials to the workstation that is running low on material and pauses supplying materials to the workstation that is full. This demand-driven scheduling logic is not standard design in the steel reinforcement processing industry; conventional designs are task-driven.

[0097] The end-face inspection results are sent synchronously across processes. The conventional approach is for each process to inspect and align itself independently, with end-face quality only affecting the sawing station itself. Downstream processes then re-align themselves after receiving the rebar. This solution transmits end-face quality information downstream in advance, allowing downstream processes to pre-adjust their processing positions based on end-face deviations before processing, eliminating the cumulative transmission of end-face errors downstream. This cross-process linkage of upstream inspection and downstream pre-compensation is not a standard design in traditional rebar processing lines, where each process operates independently in a closed loop.

[0098] The threaded rebar bending and the non-threaded bending processes share the same bending station, operating on two separate paths. Conventionally, the threading and bending lines are separate lines; threaded rebar is stored on the line first and then reloaded for bending. This solution allows threaded rebar to be directly delivered to the bending station from the finished threaded rebar storage area, while non-threaded rebar is directly allocated to the bending station from the conveying and distribution station. Both paths share the same bending equipment. This dual-line integration layout is not immediately obvious, as conventional design approaches separate different process lines. Merging the bending stations of the two lines together logically breaks with this conventional approach.

[0099] Preferably, in the first step, after the bundled steel bars are hoisted to the vibratory laying station, the vibration frequency is 20-50Hz and the vibration time is 10-30 seconds, so that the bundled steel bars are evenly laid along the width direction, and the thickness of the steel bar layer after laying does not exceed 300mm; the laid steel bars are lifted one by one, with a lifting interval of 500-1000mm, and then conveyed forward; during the conveying process, the diameter of the steel bars is detected, and the diameter measurement method is (using a photoelectric diameter gauge, two sets of photoelectric probes can be symmetrically arranged along the radial direction of the steel bars as needed, with a detection range of φ12-φ40mm), and steel bars of different diameter specifications are diverted to the corresponding conveying channels according to the detection results, with a diversion accuracy of ±0.5mm.

[0100] This technical solution addresses the problem of bundled steel bars becoming entangled and unable to be separated one by one after being hoisted. It adopts a method of vibrating and laying flat in combination with lifting one bar at a time to achieve automatic separation and feeding of raw materials.

[0101] The vibration frequency is 20-50Hz, the vibration time is 10-30 seconds, and the thickness after laying does not exceed 300mm. These parameters were determined through experiments. If the frequency is too low, the steel bars will not be vibrated enough. If the frequency is too high, the steel bars will jump up and not be able to be laid out. If the time is too short, the laying will be uneven. If the time is too long, the efficiency will be low.

[0102] The steel bars are lifted one by one, with a lifting interval of 500-1000mm, instead of being transported in batches. Only one steel bar is lifted at a time to ensure that only one steel bar enters the next process at a time. This individual lifting method is not a conventional design, as conventional feeding involves batch transport.

[0103] Preferably, in the second step, the steel bars of each specification are cut to the specified length according to the production schedule. The specified length ranges from 3 to 12 meters, and the specified length accuracy is ±1mm. After cutting, the end face of the steel bar is inspected for perpendicularity deviation and burr height. The threshold for perpendicularity deviation is 0.5mm, and the threshold for burr height is 1.0mm. When the perpendicularity deviation or burr height exceeds the threshold, the steel bar is diverted to the rework station and enters the next process after the end face is processed to meet the requirements.

[0104] This technical solution addresses the issue of verticality deviations and burrs easily occurring on the rear face of band saw cutters, where traditional methods do not involve inspection and allow the material to flow directly into the next process. Instead, it employs online end-face inspection combined with a non-conforming material diversion method.

[0105] End face inspection provides a basis for compensation in downstream processes. In conventional practices, the quality of the sawed end face is the responsibility of the sawing station; if the inspection fails, it is re-sawed, and if it passes, it is shipped out. However, this solution transmits the end face quality information to each downstream station, which then pre-adjusts the processing position based on the end face deviation.

[0106] The standard length ranges from 3 to 12 meters, with a standard length accuracy of ±1mm. This accuracy is particularly critical in a 1-to-4 material supply system. Because the four downstream stations have different requirements for the standard length, if the standard length is inaccurate, problems such as insufficient rebar length after threading and excessive rebar length after bending will occur.

[0107] The end face perpendicularity deviation threshold is 0.5mm, and the burr height threshold is 1.0mm; to ensure that the end face quality meets the downstream processing requirements.

[0108] Preferably, in the third step, the cut steel bars enter the conveying line at a speed of 5-15 m / min; during the conveying process, the long steel bars are supported by a follow-up support, which is arranged at intervals along the conveying direction at a distance of 2-5 meters, with a lifting stroke of 200-500 mm. When the follow-up support is used, the material support surface and the bottom surface of the steel bar are kept at a gap of 10-30 mm; and automatic centering is performed, with the centering method being (centering on both sides, which is automatically adjusted according to the diameter of the steel bar), and the centering accuracy being ±2 mm.

[0109] This technical solution addresses the problem of long steel bars deflecting and sagging due to their own weight during long-distance transportation, leading to conveyor deviation and material jamming. It employs interval-based follow-up supports.

[0110] Steel bars are slender rods. When the conveying distance exceeds a certain length, the weight of the steel bars will cause the middle part to sag.

[0111] The equipment in this solution can be controlled to lift and lower when the steel bar has not arrived, so as not to affect the conveying; when the steel bar arrives, it is raised to support the bottom of the steel bar.

[0112] The spacing between guide wheels is automatically adjusted according to the diameter of the reinforcing bars, with an alignment accuracy of ±2mm. Follow-up supports are arranged at intervals along the conveying direction, with a spacing of 2–5 meters.

[0113] Preferably, in the third step, the storage status of each downstream processing station and the remaining processing time of the currently being processed are collected in real time, and the conveying path is dynamically adjusted according to priority rules based on the storage threshold of each station and the remaining processing time.

[0114] The priority rule is as follows: when the material storage level of a downstream workstation is lower than the set lower limit, or when the remaining processing time of the currently being processed task exceeds the set threshold, the priority of that workstation is increased, and steel bars are preferentially allocated to that workstation.

[0115] When the material storage level of a downstream workstation is higher than the set upper limit, the priority of that workstation is reduced and the allocation of steel bars to that workstation is suspended. The material storage level threshold is divided into three levels: low alarm threshold, medium normal threshold, and high full material threshold.

[0116] This technical solution addresses the problems of cycle time conflicts between workstations, waiting for material and machine downtime, and material backlog that often occur when a multi-station parallel feeding system is used. It adopts a dynamic priority scheduling method based on three levels of material storage thresholds.

[0117] Unlike traditional production lines that use fixed production sequences or manual scheduling, this solution divides the material storage locations at each workstation into three threshold levels.

[0118] The scheduling logic is driven by the urgency of demand, not by tasks. Conventional production line scheduling follows a task-by-task order, processing tasks first and those later. This logic works fine when the cycle times of a single workstation or all workstations are consistent, but it causes problems when four workstations have inconsistent cycle times—threading is fast, anchor bolting is slow. If scheduling is based on task order, the threading workstation quickly accumulates material while the anchor bolting workstation is still waiting. This solution does not consider task order; it only considers the material storage space at each workstation, prioritizing the workstation that is about to run out of material. This demand-urgency-driven scheduling logic is not a standard design in the steel reinforcement processing industry.

[0119] This scheme has three levels: low-level alarm, mid-level normal, and high-level full. Priority is only adjusted when the storage level deviates from the mid-level and enters the low or high-level range; normal material supply occurs during the mid-level range. This three-level threshold design ensures the stability of the scheduling.

[0120] The remaining processing time of the currently processing task is also used as a scheduling input, not just based on the material storage level. Looking only at the material storage level might lead to misjudgments such as "there's enough material, but at this speed it will take a long time to complete," or "the storage level seems sufficient, but the processing will actually be finished soon." This solution uses the remaining processing time of the currently processing task as a scheduling input, combining it with the material storage level to determine priority, thus improving scheduling accuracy. This dual-input scheduling method of material storage level + remaining processing time is not a conventional design.

[0121] If the material storage level is below the lower limit, or the remaining processing time of the currently being processed task exceeds the threshold, the priority is increased. Priority is increased if either one of the following conditions is met: either the material is almost gone, or the current task is almost finished. Both situations indicate that the workstation is about to need material and requires priority supply.

[0122] Preferably, in the fourth step, the steel bars allocated to the temporary storage area of ​​the threading processing station are transferred to complete the threading process after lateral translation and flipping; the lateral translation is carried out by (truss robot translation, translation speed is 0.5~2m / s, translation stroke is 1~3 meters), and the flipping is carried out by (pneumatic flipping, flipping angle is 180°, flipping time is 2~5 seconds); the threading processing time is 30~40 seconds / piece, and the threading length is 50~100mm; the steel bars after threading are stored in the finished threading storage area, which is a two-level silo structure, and each silo can store 2~5 tons of steel bars.

[0123] This technical solution addresses the problem that rebars need to be flipped and positioned during threading, and that traditional manual flipping is inefficient and unsafe. It adopts an automatic transfer method that combines the existing truss robot's lateral translation with the existing pneumatic flipping.

[0124] The gantry robot has a translation speed of 0.5–2 m / s and a translation stroke of 1–3 meters, avoiding the positioning errors and efficiency fluctuations of manual handling.

[0125] The pneumatic flipping angle is 180°, and the flipping time is 2-5 seconds. This solution uses pneumatic flipping to reduce the flipping time to 2-5 seconds, without occupying the cycle time of threading.

[0126] The finished wire threading storage area has a two-level silo structure, with each level holding 2 to 5 tons. The two-level structure allows for the storage of finished wire threading products of different specifications in different layers, enabling the classified storage of finished wire threading products of multiple specifications without the need for manual sorting.

[0127] Preferably, in the fifth step, the steel bars allocated to the temporary storage area of ​​the anchor bolt processing station are transferred to complete the anchor bolt processing after being horizontally moved and flipped; the anchor bolt processing can be a single-head processing and grinding process of 3 to 12 meters, and the double-headed ones can be processed and stored separately; the steel bars after the anchor bolt processing is completed are stored in the finished anchor bolt storage area, which is a three-level silo structure, and each silo can store 2 to 5 tons of steel bars.

[0128] The two ends of an anchor bolt are processed and stored separately, not simultaneously. This is because the two ends of an anchor bolt are not necessarily processed in the same way—some anchor bolts have one end threaded and the other ground, while others have both ends threaded. If both ends were processed simultaneously, the different processing techniques at each end would prevent simultaneous work. This solution uses separate processing and storage for each end, allowing the two ends of an anchor bolt to be processed at different times and using different processes. The processed ends are then stored in separate silos, adapting to the different processing requirements at both ends of the anchor bolt.

[0129] The anchor bolt finished product storage area has a three-level silo structure, which is one level higher than the two-level silo for threading. Because anchor bolts come in two finished product types, single-headed and double-headed, the three-level silo can store different types of finished anchor bolts separately, achieving more precise classification and storage.

[0130] Anchor bolt processing can involve single-head machining and grinding processes ranging from 3 to 12 meters. This range covers the commonly used anchor bolt lengths in engineering projects. Anchor bolts that are too short have no engineering value, while anchor bolts that are too long are inconvenient to process and transport. This range is determined based on the actual needs of the project.

[0131] Preferably, in the sixth step, the threaded steel bars are conveyed from the threaded finished product storage area to the bending processing station at a conveying speed of 3 to 10 m / min; the steel bars that do not require threading are distributed to the temporary storage area of ​​the bending processing station via the conveying and diversion station; the bending is completed according to the set bending radius and bending angle, with the bending angle ranging from 1 to 5°; the bending speed is 5 to 15 m / min; and the formed steel bars are stored in the bending finished product storage area.

[0132] This technical solution addresses the problem of deviation between the formed radius and the set radius caused by elastic rebound after bending of reinforcing bars. It employs an over-bending angle compensation method for bending. Reinforcing bars are elasto-plastic materials; after bending and unloading, they will rebound due to elastic recovery, resulting in an actual bending radius greater than the set radius.

[0133] The 1-5° range covers the springback compensation requirements of φ16-φ32mm steel bars within the commonly used bending radius range, ensuring that steel bars of different specifications can be bent into accurate arcs.

[0134] The threaded bending and the non-threaded bending follow two paths that share the same bending station, rather than being two independent bending lines. This solution merges the two paths into one bending station, which requires solving a series of problems such as the intersection of logistics between the two paths, cycle matching, and the positioning of the rebar after threading. From a layout logic perspective, it breaks away from the conventional approach of having different process lines operate independently.

[0135] The bending speed should be 5–15 m / min. This speed range is crucial for large-radius bends. If the bending speed is too fast, the rebar will spring back excessively and the bending will be inaccurate; if it is too slow, the efficiency will be low.

[0136] Preferably, in the seventh step, the steel bars allocated to the temporary storage area of ​​the horizontal bending station are bundled and bent into shape; the number of bundles is: 3-4 φ16 steel bars and 4-5 φ12 steel bars; after bending, the steel bars are turned over and transferred to the unloading station. The turning is carried out by cylinder-driven turning, with a turning angle of 90° and a turning time of 3-8 seconds; the unloading station can be equipped with an industrial robot or a gantry robot to complete the finished product stacking.

[0137] This technical solution addresses the problems of low single-piece bending efficiency and high labor intensity of manual material handling and unloading in traditional horizontal bending machines by adopting a bundle bending process combined with automatic material handling and unloading.

[0138] The pneumatic cylinder-driven turning mechanism achieves a 90° turning angle and a turning time of 3-8 seconds, significantly faster than hydraulic turning. Bent rebars require turning before unloading; traditionally, this is done manually or with a hydraulic turning frame. Hydraulic turning frames typically take 15-30 seconds, while pneumatic turning only takes 3-8 seconds. This speed is crucial for the cycle time of bundle bending—bundling bending is highly efficient, and slow turning reduces the cycle time. This solution uses pneumatic cylinder turning to reduce the turning time to 3-8 seconds, without slowing down the bundle bending cycle.

[0139] The unloading station can be equipped with industrial robots or gantry robots as needed to complete the finished product stacking, instead of relying solely on manual stacking. Traditional horizontal bending machines require manual stacking after bending, but this solution reserves the need for robots or gantry robots, enabling automatic stacking and achieving full automation from bending and forming to stacking.

[0140] Preferably, in the eighth step, the steel bars in each finished product storage area are diverted to the corresponding finished product storage area according to their specifications. The sorting method is (sorting according to the diameter and length of the steel bars, with steel bars of different specifications stored in different finished product storage areas); the short material generated during the sawing process is detected in length, and short material with a length less than the set length threshold is moved to the surplus material collection area. The short material length threshold is 300mm.

[0141] This technical solution addresses the problems of low efficiency in manual sorting and short materials being mixed into finished products after multi-specification finished product production lines. It adopts an automatic sorting method based on specifications combined with automatic recycling of short materials.

[0142] This solution sorts products based on both diameter and length, rather than just diameter. This dual-dimensional sorting system achieves more precise product classification.

[0143] The short material length threshold is 300mm. Short materials shorter than 300mm are automatically pushed into the waste material collection area. Short materials are inevitably generated during the sawing process. If short materials are mixed into the finished product, it will cause the problem of insufficient length when used later.

[0144] The conventional approach is to manually pick out short materials, but this solution automatically collects short materials through length detection, ensuring that no short materials are mixed into the finished product.

[0145] Short pieces generated during the sawing process are automatically recycled, instead of being sorted out after the finished product comes off the line. This solution detects the length of short pieces after sawing and directly sends them to the waste material collection area, preventing short pieces from flowing into downstream processes and reducing ineffective processing in downstream processes.

[0146] Preferably, the method further includes an intelligent scheduling and control step: the processing tasks of each workstation are uniformly scheduled through the existing MES production system, the processing status, storage status and equipment operation status of each workstation are collected in real time, and the processing sequence and processing rhythm of each workstation are dynamically adjusted according to the production plan to achieve simultaneous operation of each workstation.

[0147] This technical solution addresses the problem of low overall efficiency caused by the independent operation of each workstation and the lack of unified scheduling in parallel production of one to four workstations. It adopts the existing MES production system to uniformly schedule each workstation.

[0148] The data collected includes not only processing status but also storage location status and equipment operating status. This solution uses storage location and equipment operating status as scheduling inputs to ensure the real-time nature and accuracy of scheduling decisions; it not only knows how much has been processed but also how much material remains and the condition of the equipment.

[0149] The processing sequence and pace are dynamically adjusted according to the production schedule. This solution adjusts in real time, and when a certain workstation malfunctions or is waiting for materials, the production sequence is automatically adjusted to allow other workstations to process first, thereby improving the overall efficiency of the entire production line.

[0150] This solution enables simultaneous operation at all four workstations, allowing for simultaneous sawing, threading, anchoring, bending, and horizontal bending, significantly improving the overall efficiency of the production line.

[0151] Preferably, after detecting the diameter of the reinforcing bar in the first step, the diameter specification information is simultaneously sent to each downstream processing station, and each processing station automatically adjusts the processing parameters according to the diameter specification of the reinforcing bar.

[0152] For example, the threading station automatically adjusts the spacing between the thread rolling wheels and the threading speed according to the diameter of the rebar, and the bending station automatically adjusts the bending radius compensation amount according to the diameter of the rebar.

[0153] This technical solution addresses the problem of low efficiency and error-proneness in manual parameter switching at each workstation during multi-specification mixed-line production. It adopts a linkage method that synchronizes upstream diameter detection information across processes to downstream workstations.

[0154] The threading station automatically adjusts the spacing between the thread rolling wheels and the threading speed according to the diameter; this solution automatically adjusts based on the diameter information transmitted from upstream, achieving continuous operation and no manual intervention when changing specifications.

[0155] The bending station automatically adjusts the bending radius compensation based on the diameter, eliminating the need for manual adjustment. This solution quickly adjusts the compensation amount based on the diameter information transmitted from upstream, eliminating errors from manual adjustments.

[0156] Downstream workstations no longer need to be equipped with separate diameter measurement devices. This is because the diameter information has already been measured and synchronized upstream, reducing the investment in redundant measurement equipment and minimizing secondary errors introduced by repeated measurements. If each workstation measured its own diameter, the measured values ​​might be inconsistent, introducing new errors. This upstream measurement and downstream sharing approach is not a conventional design.

[0157] Preferably, after detecting the end face perpendicularity deviation and burr height in the second step, the end face quality information is simultaneously sent to each downstream processing station; the threading processing station automatically adjusts the bar clamping position according to the end face perpendicularity deviation, and the bending processing station automatically adjusts the bending start position according to the end face perpendicularity deviation.

[0158] This technical solution addresses the problem of cumulative transmission of sawing end face errors to downstream processes and the traditional problem of independent alignment in each process. It adopts a linkage method that synchronizes end face detection information across processes to each downstream workstation.

[0159] The threading station automatically adjusts the rebar clamping position based on the end face perpendicularity deviation, rather than aligning it after clamping. The conventional method is that after the rebar is clamped, the threading machine automatically aligns the end face; if the end face is misaligned, the alignment mechanism will push the rebar straight. However, the alignment mechanism has a limited stroke; if the end face misalignment is too large, it will fail to align correctly. This solution pre-adjusts the clamping position based on the end face deviation data transmitted from upstream before clamping, eliminating the impact of end face misalignment on threading accuracy and avoiding the problem of insufficient stroke in the alignment mechanism.

[0160] The bending station automatically adjusts the starting position of the bend based on the perpendicularity deviation of the end face, rather than adjusting it after bending. This solution adjusts the starting position based on the end face deviation before bending, ensuring the alignment accuracy of the bend's starting point.

[0161] Synchronization of end-face quality information allows downstream workstations to automatically adjust processing parameters based on the data. This solution directly drives equipment adjustments using inspection data, achieving closed-loop cross-process error compensation.

[0162] Preferably, the method further includes a data acquisition and remote monitoring step: multi-dimensional automatic data acquisition is achieved through the existing production management system, and the acquired content includes the processing quantity, processing time, equipment operating status, and fault alarm information of each workstation.

[0163] This technical solution addresses the problems of traditional steel bar processing production lines lacking data acquisition and remote monitoring, failing to detect equipment malfunctions in a timely manner, and not being able to grasp production status in real time. It adopts the existing production management system to achieve automatic data acquisition from multiple perspectives.

[0164] It collects not only production data, but also equipment operating status and fault alarm information; by collecting equipment operating status and fault alarms, it can realize real-time early warning of equipment faults; instead of waiting until the equipment is completely stopped to discover the fault, it will issue an early warning when the operating status is abnormal.

[0165] Multi-dimensional automatic data collection, not single-point collection. Conventional data collection only collects one indicator, output, while simultaneously collecting data from multiple dimensions such as processing quantity, processing time, equipment operating status, and fault alarms, to achieve comprehensive perception of production status.

[0166] Automatic data collection; data is automatically collected through the existing production management system, eliminating errors and delays caused by manual recording.

[0167] The present invention also provides an intelligent steel bar sawing, threading, bending and arc bending production line with four stations, which specifically includes a material feeding and sorting station, a sawing station, a conveying and diverting station, a threading processing station, an anchor processing station, an arc bending processing station, a horizontal bending station and a sorting station arranged in sequence according to the processing flow.

[0168] The material feeding and distribution station sequentially completes the steps of vibrating and laying the steel bars, lifting and conveying them, and measuring and diverting them.

[0169] The sawing station sequentially completes the steps of fixed-length conveying, sawing and cutting, and end-face inspection.

[0170] The conveying and diversion station completes the long material follow-up support, guide and center, and dynamically allocates the conveying path steps according to the needs of the downstream station.

[0171] The threading processing station sequentially completes the steps of lateral transfer, flipping, thread rolling, and temporary storage of the finished threaded product.

[0172] The anchor bolt processing station sequentially completes the steps of lateral transfer, flipping, anchor bolt processing, and temporary storage of finished anchor bolts.

[0173] The bending processing station completes the bending forming and temporary storage of the finished bending products.

[0174] The horizontal bending station sequentially completes the steps of bundle bending, material turning, and material unloading and transfer.

[0175] The sorting station completes the steps of classifying and storing finished products and recycling short and surplus materials.

[0176] The discharge end of the feeding and sorting station is arranged opposite to the feed end of the sawing station, and the discharge end of the sawing station is arranged opposite to the feed end of the conveying and diverting station.

[0177] The first discharge end of the conveying and diverting station is arranged opposite to the feed end of the threading processing station; the second discharge end of the conveying and diverting station is arranged opposite to the feed end of the anchor bolt processing station; the third discharge end of the conveying and diverting station is arranged opposite to the feed end of the bending processing station; and the fourth discharge end of the conveying and diverting station is arranged opposite to the feed end of the horizontal bending station.

[0178] The discharge ends of the threading station, the anchor bolt processing station, the arc bending station, and the horizontal bending station are respectively arranged opposite to the feed end of the sorting station.

[0179] This technical solution addresses the problems of large footprint and high investment caused by the dispersed layout of various processes in traditional steel bar processing and the separate supply of materials by multiple sets of equipment. It adopts a one-to-four integrated layout with eight workstations arranged in sequence according to the processing flow.

[0180] The four discharge ends of the conveying and diversion station correspond to the four downstream stations respectively. It is not a simple mechanical diversion of one to four, but a one-to-four diversion with dynamic scheduling. The storage position of each downstream station is monitored in real time, and the material is sent to the branch line where it is needed, so as to achieve self-balancing of the cycle time of the multi-station.

[0181] The discharge end of the threading station is connected to the feed end of the bending station, realizing direct conveying of the bending after threading: the discharge end of the threading station is directly connected to the feed end of the bending station, and the threaded steel bars are directly sent to the bending station, shortening the logistics path of bending after threading.

[0182] The eight workstations are arranged sequentially according to the processing flow, rather than being scattered: the materials are arranged sequentially according to the processing flow, and the materials flow directly between the workstations, reducing transfer links and transfer time.

[0183] Preferably, the material feeding and sorting station is connected to the sawing station, and the sawing station is connected to the conveying and diversion station via conveyor lines. This solution uses direct conveyor line connections, allowing materials to flow automatically between stations and reducing transfer steps.

[0184] The three workstations are connected in sequence by a conveyor line to form a continuous material flow, rather than a discontinuous transfer; the continuous flow of materials improves overall efficiency.

[0185] Preferably, the conveying and diversion station is connected to the threading station and the anchor bolt processing station via lateral transfer.

[0186] The material conveying and diversion station is connected to the threading and anchoring stations via lateral transfer, not longitudinal transfer. In this solution, the threading and anchoring stations are located to the side of the conveying and diversion station and are connected via lateral transfer, shortening the material conveying path.

[0187] The lateral transfer connects two downstream workstations, realizing two branches in a one-to-four system. This solution features lateral branching, resulting in a more compact layout.

[0188] Preferably, the conveying and diversion station is connected to the bending and arc processing station and the horizontal bending station via conveyor lines.

[0189] The conveyor branching station is connected to the bending and horizontal bending stations via a conveyor line, realizing the other two branches of the one-to-four system. The conventional approach is that the bending and horizontal bending stations are fed independently, but this solution directly feeds materials from the conveyor branching station through the conveyor line, realizing one sawing unit supplying materials to four downstream stations.

[0190] The curved and horizontal bending are on the same side and connected by a conveyor line, resulting in a compact layout. This solution centrally arranges the four downstream workstations, reducing the floor space required.

[0191] Preferably, the discharge end of the threading station is connected to the feed end of the bending station, and the threaded steel bars are transported to the bending station via the threaded finished product storage area.

[0192] This solution uses a conveyor line for direct connection, allowing threaded steel bars to be directly sent for bending, thus shortening the logistics path.

[0193] After threading, the reinforcing bars are conveyed through the finished threading storage area, rather than being directly fed from the threading machine to the bending area. The finished threading storage area acts as a buffer, and the cycles of threading and bending do not need to be strictly synchronized, thus decoupling the cycles of the two stations.

[0194] Preferably, the discharge ends of the four downstream processing stations are respectively connected to the inlet ends of the sorting station, and the finished steel bars are collected and transported to the sorting station.

[0195] The outputs from the four downstream stations are all collected at the sorting station, achieving unified sorting; the finished products from the four stations are all collected at the sorting station, automatically sorted and classified for storage, reducing manual sorting steps.

[0196] Finished steel bars are collected and transported to the sorting station instead of being stored separately; this solution collects them all at the sorting station and automatically sorts them by specifications, improving sorting efficiency.

[0197] As optional configurations: the feeding and distributing station can be implemented using, but is not limited to, existing technologies such as vibrating paving equipment combined with lifting conveying equipment and diameter measuring and diversion equipment; the sawing station can be implemented using, but is not limited to, existing technologies such as band sawing equipment combined with fixed-length conveying equipment and end-face inspection equipment; the conveying and diversion station can be implemented using, but is not limited to, existing technologies such as extended conveyor lines combined with lifting material support equipment and guiding and centering equipment; the threading processing station can be implemented using, but is not limited to, existing technologies such as lateral translation equipment combined with flipping equipment and thread rolling equipment; the finished product storage area of ​​the threading processing station can adopt a two-stage silo structure; the anchor bolt processing station can... The process can be implemented using, but is not limited to, existing technologies such as lateral translation equipment, flipping equipment, and special anchor bolt processing equipment; the finished product storage area of ​​the anchor bolt processing station can adopt a three-level silo structure; the bending processing station can be implemented using, but is not limited to, existing technologies such as bending forming equipment, in conjunction with bending angle adjustment equipment; the horizontal bending station can be implemented using, but is not limited to, existing technologies such as bundle bending equipment, in conjunction with flipping equipment and unloading equipment; the horizontal bending station can also be equipped with industrial robots or gantry robots to complete finished product stacking; the sorting station can be implemented using, but is not limited to, existing technologies such as sorting and conveying equipment, in conjunction with finished product storage area and waste material collection area.

[0198] In summary, by integrating sawing, threading, grinding, anchoring, bending, arc bending, and automatic raw material feeding, fully automated production from raw materials to finished products can be achieved. This not only further improves production efficiency, but also enhances product quality and stability. This intelligent production line saves 3-5 workers, increases production efficiency by 2-3 times, and significantly reduces labor intensity. The equipment's noise reduction technology has been optimized and upgraded to lower noise levels, thereby mitigating occupational hazards for frontline workers and ensuring greater safety.

[0199] The equipment's advantages lie in its high degree of automation and intelligence, which can significantly improve production efficiency, reduce labor costs, and ensure product quality. It also integrates with a smart management system, facilitating digital management of the factory.

[0200] It also boasts the following advantages: It enables high-speed, precise automatic sawing, threading and grinding, anchor bolting, bending, and arc bending operations, significantly improving production efficiency. This production line integrates automatic feeding, automatic sawing, and automatic conveying to threading and grinding, anchor bolting, bending, and arc bending functions, substantially improving the production efficiency and quality of reinforcing bars. It features intelligent identification, intelligent control, and intelligent monitoring functions, automatically adjusting parameters and equipment status according to production needs, enhancing the level of intelligence in the production process.

[0201] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention. For those skilled in the art, any alternative improvements or transformations made to the implementation of the present invention fall within the protection scope of the present invention.

[0202] Any aspects of this invention not described in detail are well-known to those skilled in the art.

Claims

1. A smart rebar sawing, threading, bending, and arc-bending production line with four separate lines, characterized in that: The specific processing method of the production line during operation includes the following steps: The first step is to complete the laying out, specification identification, and sorting of raw materials; Bundles of steel bars are hoisted to the vibratory leveling station, where vibration causes the raw materials to be evenly laid along the width direction; the laid steel bars are then lifted one by one and conveyed forward. The second step is to cut the steel bars of various specifications after they have been diverted to the required length. Steel bars of various specifications are cut to the specified length according to the production schedule; the end face of the cut steel bars is inspected for perpendicularity deviation and burr height. The third step is to distribute the cut steel bars to downstream workstations according to their needs. After being cut to length, the steel bars enter the conveyor line. During the conveying process, the long steel bars are supported and automatically centered. The fourth step involves transferring the reinforcing bars allocated to the temporary storage area of ​​the threading station after lateral translation and flipping to complete the threading process; the threaded reinforcing bars are then stored in the finished threading storage area. The fifth step involves transferring the reinforcing bars allocated to the temporary storage area of ​​the anchor bolt processing station after lateral translation and flipping to complete the anchor bolt processing; the reinforcing bars after the anchor bolt processing is completed are then stored in the finished anchor bolt storage area. The sixth step involves transporting the steel bars that need to be bent along two paths to complete the bending process. Step 7: The steel bars allocated to the temporary storage area of ​​the horizontal bending station are bundled and bent into shape; after bending, the steel bars are turned over and transferred to the unloading station. The eighth step involves classifying and storing the finished steel bars processed at each workstation, and recycling any remaining materials.

2. The intelligent rebar sawing, threading, bending, and arc-bending production line with four separate lines as described in claim 1, characterized in that: In the first step, after the bundled steel bars are hoisted to the vibrating and leveling station, the vibration frequency is 20-50Hz and the vibration time is 10-30 seconds, so that the bundled steel bars are evenly laid along the width direction. The thickness of the steel bar layer after leveling does not exceed 300mm. After leveling, the steel bars are lifted one by one at a time with a lifting interval of 500-1000mm, and then conveyed forward. During the conveying process, the diameter of the steel bars is detected, and steel bars of different diameter specifications are diverted to the corresponding conveying channels according to the detection results, with a diversion accuracy of ±0.5mm.

3. The intelligent rebar sawing, threading, bending, and arc-bending production line with four separate lines as described in claim 1, characterized in that... In the second step, steel bars of various specifications are cut to the specified length according to the production schedule. The specified length ranges from 3 to 12 meters, and the dimensional accuracy is ±1mm. After cutting, the end face of the steel bar is inspected for perpendicularity deviation and burr height. The threshold for perpendicularity deviation is 0.5mm, and the threshold for burr height is 1.0mm. When the perpendicularity deviation or burr height exceeds the threshold, the steel bar is diverted to the rework station and enters the next process after the end face is processed to meet the requirements.

4. The intelligent rebar sawing, threading, bending, and arc-bending production line with four separate lines as described in claim 1, characterized in that: In the third step, the cut steel bars enter the conveying line at a speed of 5-15 m / min. During the conveying process, the long steel bars are supported by a follow-up support. The follow-up support is arranged at intervals along the conveying direction, with a spacing of 2-5 meters and a lifting stroke of 200-500 mm. When the follow-up support is in place, the material support surface and the bottom surface of the steel bar maintain a gap of 10-30 mm. The support is also automatically centered.

5. The intelligent rebar sawing, threading, bending, and arc-bending production line with four separate lines as described in claim 1, characterized in that: In the third step, the storage status of each downstream processing station and the remaining processing time of the currently being processed are collected in real time, and the conveying path is dynamically adjusted according to the storage threshold and remaining processing time of each station based on priority rules. The priority rule is as follows: when the material storage level of a downstream workstation is lower than the set lower limit, or when the remaining processing time of the currently being processed task exceeds the set threshold, the priority of that workstation is increased, and steel bars are preferentially allocated to that workstation. When the material storage level of a downstream workstation is higher than the set upper limit, the priority of that workstation is reduced and the allocation of steel bars to that workstation is suspended. The material storage level threshold is divided into three levels: low alarm threshold, medium normal threshold, and high full material threshold.

6. The intelligent rebar sawing, threading, bending, and arc-bending production line with four separate lines as described in claim 1, characterized in that... In the fourth step, the steel bars allocated to the temporary storage area of ​​the threading processing station are transferred to complete the threading process after being horizontally moved and flipped. The threading processing time is 30-40 seconds per piece, and the threading length is 50-100mm. After the threading process is completed, the steel bars are stored in the finished threading storage area, which is a two-level silo structure, with each silo capable of storing 2-5 tons of steel bars.

7. The intelligent rebar sawing, threading, bending, and arc-bending production line with four separate lines as described in claim 1, characterized in that... In the fifth step, the steel bars allocated to the temporary storage area of ​​the anchor bolt processing station are transferred to complete the anchor bolt processing after being horizontally moved and flipped. The anchor bolt processing can be a single-head processing and grinding process of 3 to 12 meters, and double-headed ones can be processed and stored separately. After the anchor bolt processing is completed, the steel bars are stored in the finished anchor bolt storage area. The finished anchor bolt storage area is a three-level silo structure, and each silo can store 2 to 5 tons of steel bars.

8. The intelligent rebar sawing, threading, bending, and arc-bending production line with four separate lines as described in claim 1, characterized in that: In the sixth step, the threaded steel bars are transported from the threaded finished product storage area to the bending processing station at a speed of 3 to 10 m / min; the steel bars that do not require threading are distributed to the temporary storage area of ​​the bending processing station via the conveying and diversion station; the bending is completed according to the set bending radius and bending angle, with the bending angle ranging from 1 to 5°; the bending speed is 5 to 15 m / min, and the formed steel bars are stored in the bending finished product storage area.

9. A smart rebar sawing, threading, bending, and arc-bending production line with four separate lines, characterized in that: Specifically, it includes the following stations set up in sequence according to the processing flow: material feeding and sorting station, sawing station, conveying and diverting station, threading station, anchor bolt processing station, bending station, horizontal bending station, and sorting station.

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