Steel bar sleeve cold extrusion robot system

Abstract

The utility model relates to a steel bar sleeve cold extrusion robot system which comprises a robot, a trackless electric flat trolley, a steel bar sleeve hydraulic extrusion machine and a manual operator, the robot is fixedly installed on the trackless electric flat trolley, and the trackless electric flat trolley has advancing, steering and stopping functions. The steel bar sleeve hydraulic extruding machine comprises an extruding head, an ultrahigh pressure oil pump and an oil pipe, the extruding head is installed at the head of the robot and used for extruding a steel bar connecting sleeve on the vertical face of a tunnel, different extruding dies can be selected and matched according to different requirements, and the manual operator is a unified operation terminal. The robot, the trackless electric flat trolley and the steel bar sleeve hydraulic extruding machine can be controlled at the same time. According to the utility model, automation, precision and high efficiency of steel bar connection operation can be realized in complex construction environments such as tunnels, the operation safety and the construction efficiency are obviously improved, and the human input is reduced.

Description

Technical Field

[0001] This utility model belongs to the field of tunnel engineering, and in particular relates to a cold extrusion robot system for steel bar sleeves. Background Technology

[0002] Currently, during tunnel or building construction, due to the limited length of reinforcing bars and the complex installation environment, on-site rebar splicing is often necessary. To ensure the strength and construction quality of the rebar connections, a rebar sleeve cold press is typically used to extrude and splice the rebars. This type of cold press relies primarily on manual labor to hoist the extrusion head to the work position and manually complete the extrusion operation to achieve the mechanical connection of the rebars. This method is widely used in existing engineering practices and has a certain degree of adaptability and feasibility.

[0003] However, existing cold-pressing equipment has significant shortcomings, especially when the extrusion head is large and heavy, often requiring hoisting and involving high-altitude operations, posing high safety risks. Furthermore, the entire extrusion process often relies on multiple people working together, resulting in high operational intensity and low efficiency, failing to meet the higher requirements of safety, automation, and efficiency in modern construction. Therefore, there is an urgent need to develop a structurally sound, easy-to-operate, safe, and efficient rebar sleeve extrusion system to replace the existing manual operation mode. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model provides a cold extrusion robot system for rebar sleeves, which can automate, refine, and expedite rebar connection operations in complex construction environments such as tunnels, significantly improving operational safety and construction efficiency while reducing manpower input.

[0005] To achieve the above objectives, the technical solution of this utility model is as follows:

[0006] A cold extrusion robot system for rebar sleeves includes a robot, a trackless electric flatbed trolley, a hydraulic extrusion press for rebar sleeves, and a handheld device. The robot is fixedly mounted on the trackless electric flatbed trolley, which has functions of moving, turning, and stopping. The hydraulic extrusion press for rebar sleeves includes an extrusion head, an ultra-high pressure oil pump, and oil pipes. The extrusion head is installed on the head of the robot and is used to extrude rebar connecting sleeves on the tunnel facade. Different extrusion dies can be selected according to different requirements. The handheld device is a unified operating terminal that can simultaneously control the robot, the trackless electric flatbed trolley, and the hydraulic extrusion press for rebar sleeves.

[0007] Preferably, the robot is a high-load robot, with a maximum effective arm span of not less than 2674mm and a maximum head load capacity of not less than 210kg.

[0008] Preferably, the hydraulic extrusion press for rebar sleeves is equipped with an extrusion die with three indentations, which forms three indentations on the rebar sleeve in one extrusion operation.

[0009] Preferably, the trackless electric flatbed trolley includes a steel structure body, a drive system, fixed wheel sets, steering wheel sets, a battery pack, a charger, a braking device, a control device, a remote control, a speed regulating device, a safety device, an operating device, and a safety detection device.

[0010] Preferably, the drive system includes a speed reducer motor, a drive wheel, and a braking system, wherein the speed reducer motor uses hardened gear teeth.

[0011] Preferably, the battery pack is a lithium battery pack, and the charger is a high-efficiency fully automatic charger that is equipped with the vehicle. The trackless electric flatbed cart can run continuously for 4-5 hours.

[0012] Preferably, the trackless electric flatbed trolley is equipped with a counterweight module and foldable anti-tipping support legs.

[0013] Preferably, the trackless electric flatbed trolley has a self-weight of 800kg and a counterweight module of 500kg.

[0014] Preferably, the trackless electric flatbed trolley has a design size of 1000mm×2500mm×550mm.

[0015] Preferably, the extrusion head is equipped with a pressure sensor for real-time acquisition of extrusion pressure and output to the operation interface.

[0016] Compared with the prior art, the advantages of this utility model are:

[0017] The rebar sleeve cold extrusion robot system provided by this utility model overcomes the problems of poor operational safety, high manual labor intensity, and low construction efficiency in existing technologies. It significantly improves the automation level and efficiency of rebar extrusion operations. One robot can replace the work of three or more people, reducing reliance on manpower, lowering construction intensity, and effectively avoiding the safety hazards associated with manual hoisting and high-altitude operations. The system has a high degree of structural integration and is easy to operate. Through cooperation between humans and robots, it can automatically position, stably extrude, and read and judge the extrusion pressure of the rebar sleeve, ensuring that each connection node meets the design strength requirements. At the same time, this system has good mobility, facilitating flexible deployment and movement in confined spaces such as tunnels. The overall construction process is efficient and reliable, significantly saving construction costs, ensuring the quality of rebar connections, and comprehensively improving the safety and intelligence level of construction operations. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the overall structure of the steel bar sleeve cold extrusion robot system of this utility model;

[0019] Figure 2 This is a schematic diagram of the operation process of the cold extrusion robot system for steel bar sleeves according to this utility model.

[0020] Explanation of reference numerals in the attached drawings: 1-Robot; 2-Trackless electric flatbed trolley; 3-Hydraulic extrusion press for rebar sleeves; 4-Extrusion head; 5-Rebar connecting sleeve. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model belong to the present utility model.

[0022] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to give a thorough understanding of embodiments of this application. However, those skilled in the art will recognize that the technical solutions of this application can be practiced without one or more of the specific details, or other methods, components, apparatuses, steps, etc., can be employed. In other instances, well-known methods, apparatuses, implementations, or operations are not shown or described in detail to avoid obscuring various aspects of this application.

[0023] like Figure 1As shown, this embodiment discloses a cold extrusion robot system for rebar sleeves, including a robot 1, a trackless electric flatbed trolley 2, a hydraulic extruder for rebar sleeves 3, and a handheld device. The robot 1 is fixedly installed on the trackless electric flatbed trolley 2, which has the functions of moving, turning, and stopping, and is suitable for operations in confined spaces such as tunnels, with good mobility and stability. The hydraulic extruder for rebar sleeves 3 includes an extrusion head 4, an ultra-high pressure oil pump, and oil pipes. The ultra-high pressure oil pump is the power source for extrusion, with a maximum working pressure of 80MPa, meeting the on-site requirement of 65MPa. The hydraulic extruder for rebar sleeves 3 provides high-pressure hydraulic pressure to enable the extrusion head 4 to complete the rebar extrusion. Following the action, the extrusion head 4 is installed on the head of the robot 1 and is used to extrude the rebar connecting sleeve 5 on the tunnel facade. The rebar connecting sleeve 5 is an intermediate support component that connects the rebars at both ends. Its shape matches the mold, and it can achieve a reliable connection after being stressed. Different extrusion molds can be selected according to different requirements to adapt to different specifications of rebars and connection strength requirements. The handheld device is a unified operation terminal that can simultaneously control the robot 1, the trackless electric flatbed trolley 2, and the rebar sleeve hydraulic extrusion machine 3. The handheld device has a centralized control function and can switch control targets to realize integrated operation of travel, alignment, and extrusion, reducing misoperation caused by equipment switching and improving work efficiency and safety.

[0024] Robot 1 is a high-load robot with strong load-bearing capacity and stability, suitable for carrying heavy tools to perform complex operations, especially for rebar crimping operations in narrow working spaces such as tunnels. Its robotic arm has a maximum effective reach of no less than 2674mm, allowing it to cover a large working radius and meet the needs of rebar splicing operations in different locations, providing flexible spatial adaptability. The head can bear a maximum weight of no less than 210kg, ensuring stable support of the crimping head 4 and hydraulic connectors for extended periods, preventing instability or mechanical failure due to overload.

[0025] In this embodiment, the furthest distance between the rebar sleeve and the edge of the road surface can reach 1300mm. The flatbed trolley 2 also needs to maintain a certain distance of 500mm from the edge of the road surface. Therefore, considering both the arm span requirement and the installation safety distance, a robot with an arm span of 2700mm was selected. This ensures that the robot 1 can still smoothly cover the work area and complete the rebar connection work even when the trackless electric flatbed trolley 2 is not fully in place, thereby improving the fault tolerance rate, meeting the actual needs of the equipment, and retaining a certain margin, reducing the difficulty of operation for workers, and improving the flexibility and efficiency of on-site construction. The extrusion head 4 weighs about 100kg, and the extrusion head mounting components weigh about 20kg, with a total weight of about 120kg. This constitutes the load-bearing standard required for long-term operation of the robot head. A robot with a head load of 210kg can be selected to ensure structural stability and smooth movement under long-term use, avoiding a decrease in accuracy or structural damage due to long-term load, thereby achieving reliable support for high-intensity, long-cycle operations.

[0026] Furthermore, the hydraulic extrusion press 3 for rebar sleeves is equipped with an extrusion die that creates three indentations in a single extrusion operation, which helps reduce repeated alignment and pressurization operations, improves the pace of on-site construction, and reduces the error rate. The trackless electric flatbed trolley includes a steel structure body, drive system, fixed wheel sets, steering wheel sets, battery pack, charger, braking device, control device, remote controller, speed control device, safety device, operating device, and safety detection device. The trackless electric flatbed trolley 2 includes all of the above functional modules, forming a complete electric mobile platform. The steel structure body ensures load-bearing rigidity and deformation stability. The fixed wheel sets and steering wheel sets work together to achieve smooth operation and small-radius steering. The remote controller, combined with the control device, enables remote operation. The safety detection device monitors the equipment's operating status in real time to prevent abnormalities. The speed control and braking system ensures controllable operation and provides emergency response capabilities.

[0027] In this embodiment, the drive system includes a geared motor, drive wheels, and a braking system. These components form a complete power output chain, providing continuous and reliable travel and braking capabilities. The geared motor in the drive system uses hardened gear teeth, offering advantages such as high mechanical transmission efficiency, smooth operation, and extremely low noise. This effectively improves the stability and comfort of the entire vehicle, while also providing flexible turning capabilities to meet the precise driving path requirements in confined spaces. Installation and maintenance are convenient, and the flexible rotation of each axle facilitates rapid on-site maintenance and equipment status adjustments. The drive wheels utilize a mature design and high-quality materials, featuring cast steel wheels with a rubber-coated structure. This not only enhances pressure resistance but also provides excellent shock absorption and anti-slip properties. The adhesion is uniform and bubble-free, ensuring no delamination during rolling under rated pressure, thus guaranteeing the durability and safety of the drive wheels under long-term load operation. In an emergency, the trackless transport vehicle should stop immediately by the operator using the stop button and emergency brake button on the hanging switch. This allows for an instant response to braking commands, ensuring that the equipment stops quickly and stably in case of an emergency, effectively avoiding risks such as collisions and overturning caused by inertial sliding, and improving the safety and reliability of the entire system.

[0028] The battery pack uses lithium batteries, which are characterized by high energy density, light weight, and high charging and discharging efficiency, making them easy to install on equipment and adaptable to long-term operation requirements. The charger is a high-efficiency fully automatic charger that comes with the vehicle, enabling rapid on-site charging and intelligent control, improving the continuity and convenience of operations. The trackless electric flatbed cart can run continuously for 4-5 hours, providing continuous power supply for medium-intensity shift operations, which is conducive to all-weather scheduling and cyclical operations.

[0029] In this embodiment, the robot 1 weighs 1200 kg, the extruder 3 weighs 210 kg, and the robot control cabinet weighs 50 kg, so the total system weight is approximately 1500 kg. The flatbed trolley 2 requires a load capacity of at least 1500 kg. Given the limited space in the tunnel, the width of the flatbed trolley is minimized to ensure smooth entry, exit, positioning, and turning of the equipment. Its design dimensions are 1000 mm × 2500 mm × 550 mm, with a self-weight of approximately 800 kg. The smaller width may cause the robot 1 to tip over. This embodiment adds two solutions to address this issue: a counterweight module and foldable anti-tipping outriggers to ensure stability and anti-interference capabilities even in complex terrain and under high loads. With a self-weight of 800 kg and a counterweight module of 500 kg, the robot 1's center of gravity remains within the trolley's support wheels at any position. Even in extreme postures, the robot 1 is less prone to tipping or shifting, meeting the rigid support requirements for rebar extrusion operations. The extrusion head 4 is equipped with a pressure sensor to collect the extrusion pressure in real time and output it to the operation interface. This enables pressure monitoring and real-time feedback for each extrusion process, ensuring that the crimping effect of each rebar connecting sleeve 5 meets the structural design requirements. It also prevents weak connections or rebar damage caused by insufficient or excessive extrusion pressure. The output to the operation interface facilitates construction personnel in judging the construction quality and provides a basis for subsequent data analysis or construction records.

[0030] As shown in the figure, the operation process of the rebar sleeve cold extrusion robot system in this embodiment is as follows: First, a manual operator moves the entire equipment to the target working position using a trackless electric flatbed trolley 2. Then, a manual operator moves the extrusion head 4 to the corresponding position of the rebar connecting sleeve 5 using the robot 1. Subsequently, a manual operator assists in installing the extrusion mold and starts the rebar sleeve hydraulic extrusion press 3 to perform the extrusion operation. During the extrusion process, the system reads the pressure sensor values ​​on the extrusion head 4 and the length value of the rebar connecting sleeve 5 in real time and displays them on the operation interface. When the detected extrusion pressure reaches the preset design value and the length value of the rebar connecting sleeve 5 meets the standard, the current extrusion operation is completed, and the extrusion head 4 detaches from the rebar connecting sleeve 5. If the pressure does not meet the requirements, the extrusion action continues. After extrusion is completed, a manual operator assists in disassembling the mold, and then the manual operator moves the robot 1 away from the working area. At this point, the entire rebar connection extrusion operation process ends. This process, through the precise positioning of the robot 1, the real-time feedback of the pressure sensor, and the organic combination of manual assistance, achieves efficient, safe, and standardized cold extrusion connection of the rebar sleeve 5.

[0031] In summary, this utility model provides a cold extrusion robot system for rebar sleeves, including a robot 1, a trackless electric flatbed trolley 2, a hydraulic extruder for rebar sleeves 3, and an extrusion head 4. By installing the extrusion head 4 at the end of the robot 1 and having the entire device carried by the trackless electric flatbed trolley 2, automated cold extrusion of rebar connecting sleeves 5 is achieved on the construction site. This system enables remote control, automatic alignment, and real-time pressure monitoring. It possesses technical advantages such as compact structure, high efficiency, stable operation, and high safety, significantly improving the efficiency and quality of rebar connection operations, reducing manpower burden on construction sites, and ensuring construction safety. This technology is particularly suitable for the intelligent transformation of rebar connection operations in tunnels, subways, bridges, and other scenarios, and has good prospects for widespread application. It is of great significance for promoting the transformation of construction methods in the building industry towards intelligence and mechanization.

[0032] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Under the concept of this utility model, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of this utility model as described above. For the sake of brevity, they are not provided in detail. Although this utility model 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 of the technical features. These 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 this utility model.

Claims

1. A robotic system for cold extrusion of steel bar sleeves, characterized in that, The system includes a robot (1), a trackless electric flatbed trolley (2), a rebar sleeve hydraulic extrusion machine (3), and a handheld device. The robot (1) is fixedly installed on the trackless electric flatbed trolley (2), which has the functions of moving, turning, and stopping. The rebar sleeve hydraulic extrusion machine (3) includes an extrusion head (4), an ultra-high pressure oil pump, and oil pipes. The extrusion head (4) is installed on the head of the robot (1) and is used to extrude the rebar connecting sleeves (5) on the tunnel facade. Different extrusion molds can be selected according to different requirements. The handheld device is a unified operating terminal that can simultaneously control the robot (1), the trackless electric flatbed trolley (2), and the rebar sleeve hydraulic extrusion machine (3).

2. The cold extrusion robot system for steel bar sleeves according to claim 1, characterized in that, The robot (1) is a high-load robot with a maximum effective arm span of not less than 2674mm and a maximum head load capacity of not less than 210kg.

3. The cold extrusion robot system for steel bar sleeves according to claim 2, characterized in that, The hydraulic extrusion press (3) for steel bar sleeves is equipped with an extrusion die with three indentations, which forms three indentations on the steel bar sleeve (5) in one extrusion operation.

4. The cold extrusion robot system for steel bar sleeves according to claim 3, characterized in that, The trackless electric flatbed trolley (2) includes a steel structure body, a drive system, a fixed wheel set, a steering wheel set, a battery pack, a charger, a braking device, a control device, a remote control, a speed regulating device, a safety device, an operating device, and a safety detection device.

5. The cold extrusion robot system for steel bar sleeves according to claim 4, characterized in that, The drive system includes a speed reducer motor, drive wheels, and a braking system. The speed reducer motor uses hardened gear teeth.

6. The cold extrusion robot system for steel bar sleeves according to claim 4, characterized in that, The battery pack is a lithium battery pack, and the charger is a high-efficiency fully automatic charger that is equipped with the vehicle. The trackless electric flatbed trolley (2) can run continuously for 4-5 hours.

7. The cold extrusion robot system for steel bar sleeves according to claim 4, characterized in that, The trackless electric flatbed trolley (2) is equipped with a counterweight module and a foldable anti-tipping support leg structure.

8. The cold extrusion robot system for steel bar sleeves according to claim 7, characterized in that, The trackless electric flatbed trolley (2) has a self-weight of 800kg and a counterweight module of 500kg.

9. The cold extrusion robot system for steel bar sleeves according to claim 8, characterized in that, The trackless electric flatbed trolley (2) has a design size of 1000mm×2500mm×550mm.

10. The cold extrusion robot system for steel bar sleeves according to claim 1, characterized in that, The extrusion head (4) is equipped with a pressure sensor for real-time acquisition of extrusion pressure and output to the operation interface.

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