Steel bar processing intelligent identification rib turning device

Abstract

The utility model relates to a kind of steel bar processing intelligent identification rib turning device, including rotation adjusting mechanism, traction positioning system, vision detection unit and control system cooperation constitutes, rotation adjusting mechanism is driven by servo motor driving belt transmission assembly, and steel bar rotation is realized in combination with ±0.5 ° high-precision rib turning disc;Traction positioning system is configured with pressure cylinder and roll group, and the elastic fixing and conveying of 16-32mm diameter steel bar are adapted;Vision detection unit uses 5 million pixel camera and annular light source, with 0.05mm / pixel resolution real-time capture rib feature;PLC controller is integrated each module by RJ45 network interface, and preset 1.5 ° angle threshold triggers automatic compensation instruction.The utility model solves the problem of low efficiency of traditional manual positioning, poor mechanical positioning accuracy, with high-precision, strong adaptability and full-process automation characteristics, significantly improve steel bar processing quality and efficiency.

Description

Technical Field

[0001] This utility model relates to the technical field of steel bar processing equipment for building engineering, and specifically to an automated mechanical device for adjusting the rib position of ribbed steel bars. Background Technology

[0002] In reinforced concrete structure construction, the rib position of ribbed steel bars directly affects the anchorage performance and mechanical connection accuracy of the bars. Traditional rib-turning processes often employ manual positioning or simple mechanical restraint, which has the following drawbacks:

[0003] Manual operation is labor-intensive and inefficient, making it difficult to adapt to large-scale production;

[0004] The mechanical limit accuracy is insufficient and cannot meet the requirements of high-precision engineering.

[0005] The lack of a real-time detection mechanism results in poor adaptability to changes in rebar diameter and surface condition. Therefore, there is an urgent need for a rib-rotating device that combines automation and high precision. Summary of the Invention

[0006] The purpose of this invention is to provide an intelligent rib-recognition device for steel bar processing to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, this utility model provides the following technical solution: a smart rib-recognition device for steel bar processing, comprising a rotation adjustment mechanism, a traction positioning system, a vision detection unit, and a control system;

[0008] The rotating adjustment mechanism is used to drive the steel bar to rotate in order to adjust the rib position; the traction positioning system is used to transport and fix the steel bar; the vision detection unit is used to detect the rib position of the steel bar; and the control system is used to coordinate the work of each component.

[0009] Preferably, the rotation adjustment mechanism includes a rotating rib mechanism base frame, a servo motor, a reducer, a gripper cylinder, a rotating rib disc, and a belt drive assembly;

[0010] A rib-turning disc is provided on the base frame of the rib-turning mechanism. A servo motor is provided on one side of the rib-turning disc. The servo motor drives the rib-turning disc to rotate through a reducer and a belt drive assembly. A gripper cylinder is provided on the outside of the rib-turning disc to clamp the reinforcing bar. The reinforcing bar self-traction positioning system passes through the rib-turning disc and its front end is clamped by the gripper cylinder.

[0011] Preferably, the belt drive assembly includes a driving pulley, a driven pulley, and a belt. The servo motor drives the driving pulley through a reducer, and the driving pulley drives the driven pulley and the rotating disc through the belt, achieving a rotational accuracy of ±0.5°.

[0012] Preferably, the traction positioning system includes a traction motor, traction rollers, a clamping cylinder, clamping rollers, and a rebar support roller assembly; the traction motor drives the traction rollers to transport the rebars, the rebar support roller assembly supports the axial movement of the rebars, and the clamping cylinder, in conjunction with the clamping rollers, elastically clamps the rebars.

[0013] Preferably, the clamping force of the clamping cylinder is adjustable in the range of 50-200N to accommodate the positioning of steel bars with a diameter of 16-32mm.

[0014] Preferably, the visual inspection unit includes an inspection camera, a lens, and a ring light source; the inspection camera is vertically mounted above the reinforcing bar, and uses a 5-megapixel color camera with an 8mm wide focal length lens, achieving a detection resolution of 0.05mm / pixel; the ring light source is arranged around the camera to highlight the light and shadow characteristics of the rib pattern.

[0015] Preferably, the control system includes a PLC controller, which communicates with the servo motor and the detection camera via an RJ45 network port. It employs a preset angle threshold triggering mechanism, automatically generating a rotation compensation command when a rib position deviation exceeds 1.5°.

[0016] The technical effects and advantages of this utility model are as follows:

[0017] 1. High-precision positioning and adjustment capabilities: The combination of servo motor, reducer, and belt drive, along with a rotational accuracy of ±0.5°, ensures stable and precise rotational adjustment of the reinforcing bar by the rotating rib plate; the belt drive reduces mechanical vibration and further improves the smoothness of the adjustment process; a 5-megapixel color camera with an 8mm wide focal length lens, vertically mounted above the reinforcing bar, combined with a ring light source to highlight the light and shadow characteristics of the rib pattern, achieves a detection resolution of 0.05mm / pixel, accurately capturing minute deviations in the rib position and providing reliable data support for adjustment.

[0018] 2. Highly adaptable, covering multiple specifications of steel bars: The adjustable clamping force of the clamping cylinder of the traction positioning system (50-200N) and the support design of the steel bar roller group are suitable for steel bars with a diameter range of 16-32mm. The elastic clamping avoids steel bar deformation, while the roller group reduces conveying friction, ensuring stable positioning of steel bars of different specifications during the traction process, thus expanding the applicable scenarios of the device.

[0019] 3. Full-process automated control improves efficiency and consistency: The control system communicates with the servo motor and detection camera in real time through the RJ45 network port to achieve closed-loop control of "detection-judgment-adjustment": The vision detection unit quickly identifies the rib position deviation, the control system triggers the compensation command based on the preset angle threshold (1.5°), and the rotation adjustment mechanism automatically corrects the deviation. No manual intervention is required throughout the process, which greatly improves production efficiency and product consistency and reduces the risk of human operation error.

[0020] 4. The collaborative design of each module forms an efficient process of "conveying-inspection-adjustment"; the cooperation between the gripper cylinder and the rotating rib plate ensures reliable fixing of the steel bars and avoids slippage during rotation, further improving the stability of processing quality. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of this utility model;

[0022] Figure 2 This is a top view of the present invention;

[0023] Figure 3 This is the front view of the present invention.

[0024] In the diagram: Rotary adjustment mechanism-1, traction positioning system-2, vision inspection unit-3, rib turning mechanism base frame-11, servo motor-12, reducer-13, gripper cylinder-14, rib turning disc-15, driving pulley-16, belt-17, driven pulley-18, traction motor-21, traction roller-22, clamping cylinder-23, clamping roller-24, rebar roller group-25. Detailed Implementation

[0025] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0026] like Figures 1-3 This invention illustrates a specific embodiment of an intelligent rib-recognition device for steel bar processing:

[0027] Rotation adjustment mechanism installation: Fix the base frame 11 of the rotating rib mechanism horizontally to the production line base, and calibrate it with a level to ensure that the flatness error is ≤0.1mm / m. The rotating rib plate 15 in the center of the base frame is connected to the base frame through the bearing seat, and the axial runout is ≤0.3mm.

[0028] The servo motor 12 and the reducer 13 are connected by a rigid coupling and installed on one side of the base frame to ensure that the parallelism error between the motor axis and the axis of the rotating rib is ≤0.5mm. The driving pulley 16 is fitted onto the output shaft of the reducer, and the driven pulley 18 is fixed to the edge of the rotating rib. The parallelism of the two pulleys is calibrated by a dial indicator, and the error is controlled within ±0.5mm.

[0029] The tension of belt 17 is adjusted to 60-80N via the tensioning pulley or motor mounting slot to ensure no slippage during transmission. The gripper cylinders 14 are symmetrically installed on the outside of the rotating rib plate, with the cylinder axis perpendicular to the steel bar axis. The distance between the clamping surface and the center of the rotating rib plate is adjusted according to the steel bar diameter, suitable for 16-32mm specifications.

[0030] Traction positioning system installation: The traction motor 21 and the traction roller 22 are driven by a synchronous belt and installed at the front end of the conveying track. The surface roughness of the traction roller Ra≤3.2μm ensures smooth conveying of the steel bars. The steel bar idler group 25 is evenly arranged along the conveying track. The top surface height of the idler is consistent with an error ≤0.5mm, supporting the movement of the steel bar axis.

[0031] The clamping cylinder 23 is mounted above the traction roller via a bracket. The cylinder piston rod is connected to the clamping roller 24, and the surface of the clamping roller is covered with a rubber layer (Shore hardness 60±5A) to ensure uniform elastic clamping force. The cylinder pressure is adjusted by a pressure reducing valve, making the clamping force adjustable within the range of 50-200N to meet the positioning requirements of steel bars of different diameters.

[0032] Visual inspection unit installation: Inspection camera 3 is vertically fixed 272mm directly above the rebar using a bracket, with the lens axis perpendicular to the rebar axis. During installation, a calibration plate is used for pixel accuracy calibration to ensure an inspection resolution of 0.05mm / pixel at a working distance of 272mm. An 8mm wide focal length lens is selected, covering a depth of field range of 16-32mm rebar diameter variation and 3mm vertical variation. A ring light source is arranged around the camera, with the light source plane parallel to the camera lens plane, and the distance adjusted to 50-80mm. The light source intensity is calibrated to 800-1200 lux using an illuminance meter to ensure clear rib light and shadow characteristics.

[0033] PLC Control System Configuration: The system uses an Inovance H5U series PLC as the control core, communicating with the servo motor driver and camera industrial interface via an RJ45 network port. I / O point allocation is as follows: Input points: camera detection signal, rebar positioning photoelectric signal, gripper cylinder positioning signal, etc.; Output points: servo motor start / stop commands, cylinder action control, alarm indication, etc.; An angle threshold triggering mechanism is preset in the PLC program: when the visual system detects a rib position deviation exceeding 1.5°, a rotation compensation command is automatically generated, achieving a control accuracy of ±0.5°.

[0034] Servo drive system debugging: Servo motor (12) parameter settings: rated speed 3000rpm, position loop gain 2000rad / s, speed loop gain 1500rad / s, to ensure that the rotating rib plate rotates smoothly and the positioning time is ≤0.3s; through trial operation test, adjust the acceleration and deceleration time constant so that the steel bar does not shake obviously during the rotation.

[0035] Visual inspection system calibration: The camera was calibrated using a standard rib pattern template, and the image acquisition parameters were adjusted using AugenVision software: exposure time 40ms, gain 1.2x, and automatic white balance; a rib feature recognition model was established, and the training set included images of steel bars with different degrees of corrosion and stain coverage to ensure a detection accuracy of ≥99.5%.

[0036] Workflow:

[0037] The reinforcing bar is transported to the rotating rib plate 15 by the traction roller 22, and the pressing roller 24 is used to elastically fix the position; the camera 31 collects the rib pattern image and analyzes the rib position deviation through the algorithm; if the deviation exceeds the threshold, the PLC triggers the servo motor 12 to drive the rotating rib plate 15 to rotate, and the gripper cylinder 14 locks the reinforcing bar to complete the correction; after adjustment, the reinforcing bar is output through the traction system and enters the next process.

[0038] This device, through modular collaborative design, balances high precision, strong adaptability, and automation, making it suitable for large-scale steel bar processing scenarios and significantly improving the reliability of engineering component connections.

[0039] The applicant further declares that while the above embodiments illustrate the implementation method and apparatus structure of this utility model, this utility model is not limited to the above-described embodiments, meaning that this utility model must rely on the above methods and structures to be implemented. Those skilled in the art should understand that any improvements to this utility model, equivalent substitutions for the selected implementation methods, additions of steps, and selection of specific methods all fall within the protection and disclosure scope of this utility model.

[0040] This utility model is not limited to the above-described embodiments. All methods that use similar structures and methods to achieve the purpose of this utility model are within the protection scope of this utility model.

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