Forming process of oversize annular reinforcing mesh component

Abstract

Disclosed in the present invention is a forming process for an ultra-large-diameter annular reinforcing mesh component, the forming process comprising the following steps: S1, preparing a planar reinf

Description

The present invention relates to the forming process field of reinforcing mesh components. More specifically, the present invention refers to a forming process of oversize annular reinforcing mesh component. BACKGROUND Concrete bridge towers are widely applied for long-span cable-stayed bridges and suspension bridges such as Hong Kong-Zhuhai-Macao Bridge crossing Lingdingyang Bay, Pingtang Bridge over high mountains in Guizhou Province and Erqi Changjiang River bridge in Wuhan crossing Yangtze River, and steel bar binding is also extremely important in the construction of bridge towers. Manual binding on towers is usually adopted for traditional steel bar binding and construction. Currently, steel bar binding is gradually moved to the rear area, that is, steel bars are made into mesh components and lifted to tower for splicing. Even though, reinforcing steel work is also labor-intensive and time-consuming. Steel bar component construction is one of the directions for bridge construction in the future. In the rear area, reinforcing mesh components are made mechanically and assembled into segment components in scaffold, and finally they are hoisted to the tower for splicing, so as to achieve the reinforcing mesh component construction of the bridge towers. It is able to improve the steel bar binding quality, shorten the construction duration, and effectively alleviate development problems of the industry such as labor shortage. Mechanized production of reinforcing mesh components, as the foundation of component construction for bridge towers, is generally divided into two steps, i.e., oversize flat meshes should be made and then bent to form a space structure. However, flat meshes should be bent into arcs and spliced into rings at the same time for different bridge towers, tower column section shapes and bending mechanisms and rounded cable bent tower with multi-layer main reinforcement. Then these annular meshes should be placed in scaffold, nested with each other and threaded with drag hook bars to form segment components. Due to the large area, heavy mass and excellent flexibility, production and bending of flat meshes are crucial difficulties. SUMMARY In order to realize these purposes and other advantages of the invention, a preferred embodiment of the invention provides a forming process of oversize annular reinforcing mesh component, comprising the following steps: Step SI: Prepare flat reinforcing meshes; Step S2: Bend flat reinforcing meshes into a semicircle and connect and fix two cambered reinforcing meshes to form an annular reinforcing mesh; Step S3: Connect and fix more annular reinforcing meshes into annular components. Step SI specified in another preferred embodiment of the invention comprises the following steps: Sil: Connect stirrups into through-length steel bars by means of flash butt welding, cut them based on required length and then deliver them onto the stirrup preparation table; S12: Pull the through-length steel bars on the stirrup preparation table to the plane bending mechanism with a plurality of stirrup slots that are feasible for lateral movement and drive stirrups to move and complete the plane bending; S13: Weld main reinforcements on stirrups. Once all main reinforcements are welded, the production of reinforcing mesh on a single plane is completed; S14: After the production of reinforcing mesh on planes, fix solid toolings on meshes to prevent mesh deformation during transfer and storage; SI5: Repeat S11-S14 until reinforcing meshes on all planes are produced. An arc bending device is used to bend the reinforcing meshes into a semicircle as specified in step S2. The arc bending device mentioned hereby comprises a pedestal and a plurality of arc bending mechanisms, and the pedestal hereof is semi-circular type and the arc bending mechanism hereof is distributed at intervals along the arc surface of the pedestal; The arc bending mechanism above comprises a steel bar grasping mechanism, mesh strut and power mechanism. The steel bar grasping mechanism mentioned hereby is connected to the strut of the mesh for grasping the reinforcing mesh to be arced, the steel bar grasping mechanism mentioned hereby is connected to the power mechanism, which is capable of extension and retraction as driven by the power mechanism, so that reinforcing mesh can be bent and deformed. One end of the mesh strut is connected with the steel bar grasping mechanism, and the other end can be rotated and is hinged on the rotary table. The mesh strut mentioned hereby can rotate along the shaft, i.e., the hinge point between the rotary table and the mesh strut mentioned above, so as to adjust the angle by rotating the mesh strut. As specified in another preferred embodiment of the invention, the rotary table is provided with a fixed support and a telescopic rod, and one end of the telescopic rod is connected to the mesh strut mentioned above, and the other end is connected to the fixed support, so as to control the rotation angle of the mesh strut by adjusting the length of the telescopic rod. The telescopic rod, rotary table and the fixed support, and the steel bar grasping mechanism mentioned above are respectively located on both sides of the mesh strut. As specified in another preferred embodiment of the invention, the rotary table is arranged on a sliding table that can slide along the track. The sliding table is located on one side of the mesh strut, and on the same side with the telescopic rod, rotary table and fixed support mentioned above. Step S2 specified in another preferred embodiment of the invention specifically comprises the following steps: S21: Temporarily fix reinforcing meshes. A plurality of arc bending mechanisms are distributed around the cambered surface of the pedestal at intervals, and the steel grasping mechanism mentioned in the arc bending mechanism part is located on the side that the mesh strut is far away from the pedestal. In this way, the mechanical equipment can pull the reinforcing mesh, resulting in preliminary deformation; S22: Grasp reinforcing meshes with the steel bar grasping mechanism, start the mentioned power mechanism to drive the steel bar grasping mechanism to retract and drive reinforcing meshes to move to both sides, so as to deform reinforcing meshes gradually; S23: With the gradual retraction of steel bar grasping mechanism, the reinforcing meshes gradually get close to the mesh strut and cling to the mesh strut. Once tightly clinging to the mesh strut, reinforcing meshes will hold the steel bar tightly on them; S24: Adjust the tilt disclosure of specified mesh stmt mentioned by adjusting the length of the telescopic rod according to the bending parameters related to reinforcing meshes, so that the top and bottom sizes can be different after bending reinforcing meshes; S25: According to the designed arc dimension of reinforcing meshes, all sliding tables in the arc bending mechanism move in the same direction as driven by a hydraulic cylinder. Step S2 specified in another preferred embodiment of the invention also comprises the following steps: Step S26: When the arc of the reinforcing mesh reaches the designed dimension, the size of reinforcing meshes should be ensured to meet design requirements, so as to form curved reinforcing mesh after removing the arc bending mechanism; Step S27: Connect and fix two cambered reinforcing meshes to form an annular reinforcing mesh. As specified in Step S2 of another preferred embodiment of the invention, following operations are required before arcing the flat reinforcing meshes as required by an arc bending device and performing step S21 as hereinbefore defined: S20: Temporarily fix the middle of meshes on the mesh support composed of two boards hinged on one side and a hydraulic rod between them. The fixing end of the hydraulic rod is connected with one of the boards and its telescopic end is connected to the other board. At this time, the mesh strut mentioned hereby is folded and the board connected to the fixing end of the hydraulic rod above is placed on ground; The hydraulic rod can be extended so that the board connected to the telescopic end of the hydraulic rod rotates along the other board until the board connected to the telescopic end of the hydraulic rod is perpendicular to the ground. Step S3 specified in another preferred embodiment of the invention, i.e., connect and fix other annular meshes into make annular components, specifically comprises the following steps: S31: Install the annular meshes of an inner side first, then lift other annular meshes and place them in designated position. After adjusting and confirming positions, place the next annular mesh until all annular meshes of the same section are placed; S34: Thread drag hook bars through meshes after they are completely made into annular meshes to construct a complete reinforcement component. The invention includes the following beneficial effects at least: the invention aims to mechanically produce flat reinforcing meshes, then bend them into arcs through special arc bending device, and finally splice meshes into rings and thread drag hook bars through them to form components, which can reduce the manpower input for steel bar binding, improve the steel bar binding quality, and improve the bridge tower construction efficiency. Other advantages, objectives and characteristics of the invention will be partly explained below and partly understood by the technical personnel in the field through the research and practice of the invention. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows the structure diagram of a single arc bending mechanism in the present invention. FIG. 2 shows the structure diagram of arc bending device in the present invention. FIG. 3 shows the structure diagram of mesh strut in the present invention. FIG. 4 shows the structure diagram for splicing and installation of two cambered reinforcing meshes in the present invention. DETAILED DESCRIPTION A more detailed description for the invention is given below by combining with the figures to command the technical personnel in this field to implement by referring to the contents of the Specification. The following description is intended to illustrate the invention to enable technicians of the field to embody the invention. The preferred embodiments described below are only examples, and technicians of the field can think of other obvious variations. The basic principles of the invention defined in the following descriptions may be applied to other embodiments, variations, improvements, equivalents and other technical schemes that do not deviate from the spirit and scope of the invention. It should be understood by technicians of the field that the orientation or positional relation indicated by the terms such as "lengthwise", "horizontal", "up", "down", "front" and "rear", "left", "right" and "vertical", "level", "top", "bottom", "inside" and "outside" is based on the orientation or positional relation shown in figures. This is only to facilitate the description of the invention and to simplify the description, and is not to indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, so they cannot be understood as a limitation to the invention. It also should be understood that the term "one" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element may be one, and in another embodiments, the number of the element may be multiple, so the term "one" should not be understood as a limitation of quantity. As shown in Fig. 1-4, the forming process of oversize annular reinforcing mesh component of the invention comprises the following steps: Step SI: Prepare flat reinforcing meshes; Step S2: Bend flat reinforcing meshes into semicircle and connect and fix two cambered reinforcing meshes to form an annular reinforcing mesh; Step S3: Connect and fix more annular reinforcing meshes into annular components. Step SI thereinto comprises the following steps: Sil: Connect stirrups into through-length steel bars by means of flash butt welding, cut them based on required length and then deliver them onto the stirrup preparation table; S12: Pull the through-length steel bars on the stirrup preparation table to the plane bending mechanism with a plurality of stirrup slots that are feasible for lateral movement and drive stirrups to move and complete the plane bending; S13: Weld main reinforcements on stirrups. Once all main reinforcements are welded, the production of reinforcing mesh on a single plane is completed; S14: After the production of reinforcing mesh on planes, fix solid toolings on meshes to prevent mesh deformation during transfer and storage; SI5: Repeat S11S14 until reinforcing meshes on all planes are produced. Another preferred embodiment is to use an arc bending device to arc reinforcing meshes in planes as specified in step S2. The arc bending device mentioned hereby comprises a pedestal and a plurality of arc bending mechanisms 13, and the pedestal 13 hereof is semi-circular type and the arc bending mechanism hereof is distributed at intervals along the arc surface of the pedestal 13; The arc bending mechanism above comprises steel bar grasping mechanism 10, mesh strut 6 and power mechanism 7. The steel bar grasping mechanism 10 mentioned hereby is connected to the strut 6 of the mesh for grasping the reinforcing mesh to be arced, the steel bar grasping mechanism 10 mentioned hereby is connected to the power mechanism 7, which is capable of extension and retraction as driven by the power mechanism 7, so that reinforcing mesh can be bent and deformed. In the embodiment above, all the arc bending mechanisms mentioned are located between the reinforcing mesh and pedestal 13, the steel bar grasping mechanism 10 is connected to mesh strut 6 and then controls the steel bar grasping mechanism 10 to retract, so as to pull back the reinforcing mesh to achieve the bending and deformation of the reinforcing mesh. Besides, the bending degree of the reinforcing meshes can be controlled by controlling the retraction degree of steel bar grasping mechanism 10. The specific structure of the steel bar grasping mechanism 10 is not restricted as long as reinforcing meshes can be grabbed and connected. It can be a grab hook to facilitate construction. As the section size of the bridge tower changes with the increase of the elevation, the arc radius of the bent meshes and the slope of the main reinforcement also change. In order to better achieve arc bending of reinforcing meshes, the mesh strut 6 is improved to make its angle variable. Besides, combined with the above steel bar grasping mechanism 10 that is telescopic as driven by the power mechanism 7, reinforcing meshes can be bent or deformed in arc and inner diameter. Specifically, one end of the mesh strut 6 is connected with the steel bar grasping mechanism 10, the other end is rotatable and hinged on the rotary table 3, and mesh strut 6 mentioned above can rotate along the shaft, i.e., the hinge point between the rotary table 3 and the mesh strut 6 mentioned above, so as to adjust the angle by rotating the mesh strut 6. The tilt angle of the mesh strut 6 can be manually adjusted or driven by equipment. A specific implementation mode to achieve the rotation of mesh strut 6 and adjustable tilt angle is provided below. The rotary table 3 is provided with a fixed support 4, and one end of the telescopic rod 5 is connected to the mesh strut 6 mentioned above, and the other end is connected to the fixed support 4, so as to control the rotation angle of the mesh strut 6 by adjusting the length of the telescopic rod 5. In view of the balance of the entire bending process and convenience of construction, the following arrangements are made and the mentioned telescopic rod, rotary table and the fixed support, and the steel bar grasping mechanism are respectively on both sides of the mesh strut As specified in another preferred embodiment of the invention, the rotary table is arranged on a sliding table that can slide along the track. The sliding table is located on one side of the mesh strut, and on the same side with the telescopic rod, rotary table and fixed support mentioned above. The steel bar grasping mechanism 10 is connected to the power mechanism 7 via steel wire rope 9. One end of the steel wire rope is connected to the steel bar grasping mechanism 10, the other end threads through mesh strut 6 and then connected to the power mechanism mentioned above, and the steel wire rope 9 can shuttle back and forth along the thickness of the mesh strut 6. The power mechanism 7 is an electric winch that can roll up steel wire rope conveniently and rapidly by rotation. The steel bar grasping mechanism 10 is located on the side of the mesh strut 6 away from the pedestal 13. Considering that if directly applying the rigid drag by angle inclination of mentioned mesh strut 6 and electric winch pulling the steel bar grasping mechanism 10, local stress of reinforcing mesh will be uneven, resulting in uneven local deformation. In response to it, following improvements are made in the application: the rotary table 3 can rotate around the sliding table 2 in a certain range of angles, and both of them can achieve resistance-free sliding, so if the stress is uneven when bending or pulling reinforcing meshes based on angle inclination of mentioned mesh strut 6 and electric winch pulling the steel bar grasping mechanism 10, rotary table 3 will be automatically driven around sliding table 2 until the stress is even, so that the stress of mesh will be even and bent into arcs without local uneven deformation. What needs illustration is that the number of steel bar grasping mechanism 10 mentioned can be 1 or more, and the specific number is not displayed. Multiple steel bar grasping mechanisms are preferred. More than one of it can be respectively distributed along the height direction of mentioned mesh strut 6, which can grasp reinforcing mesh in a wide range. For reinforcing meshes, the stress will be more even, which is conducive to subsequent bending. If there is only one steel bar grasping mechanism, the stress will be uneven when bending or pulling. As specified in Step S2 of another preferred embodiment of the invention, bend flat reinforcing meshes into semicircle and connect and fix two cambered reinforcing meshes to form an annular reinforcing mesh. Specifically: S20: Temporarily fix the middle of meshes on the mesh support 11 composed of two boards 111 hinged on one side and a hydraulic rod 112 between them. The fixing end of the hydraulic rod 112 is connected with one of the boards 111 and its telescopic end is connected to the other board 111. At this time, the mesh strut 11 mentioned hereby is folded and the board 111 connected to the fixing end of the hydraulic rod 112 above is placed on ground; The hydraulic rod 112 can be extended so that the board 111 connected to the telescopic end of the hydraulic rod 112 rotates along the other board 111 until the board 111 connected to the telescopic end of the hydraulic rod 112 is perpendicular to the ground. S21: Temporarily fix reinforcing mesh 12. A plurality of arc bending mechanisms are distributed around the cambered surface of the pedestal 13 at intervals, and the steel grasping mechanism 10 mentioned in the arc bending mechanism part is located on the side that the mesh strut 6 is far away from the pedestal 13. In this way, the mechanical equipment can pull the reinforcing mesh 12, resulting in preliminary deformation; S22: Grasp reinforcing meshes with the steel bar grasping mechanism 10, start the mentioned power mechanism 7 to drive the steel bar grasping mechanism 10 to retract and drive reinforcing mesh 12 to move to both sides, so as to deform reinforcing mesh 12 gradually. The power mechanism 7 mentioned hereby is an electric winch. When the electric winch pulls, the mesh strut 6 mentioned hereby can rotate with the rotary table 3, so that the reinforcing mesh is under a uniform stress and can be bent into arc without local uneven deformation. S23: With the gradual retraction of steel bar grasping mechanism 10, the reinforcing mesh 12 gradually gets close to the mesh strut 6 and cling to the mesh strut 6. Once tightly cling to the mesh strut, reinforcing mesh 12 will hold the steel bar tightly on them as the mesh strut 6 is provided with a clamping mechanism 8; S24: Adjust the tilt disclosure of specified mesh strut 6 mentioned by adjusting the length of the telescopic rod 5 according to the bending parameters related to reinforcing mesh 12, so that the top and bottom sizes can be different after bending reinforcing mesh 12. S25: According to the designed arc dimension of reinforcing mesh 12, sliding tables in many arc bending mechanisms move in the same direction at different speeds as driven by hydraulic cylinder. The speed of sliding table of the arc bending mechanism in the middle is small, but it is larger when moving to both sides. Step S26: When the arc of the reinforcing mesh 12 reaches the designed dimension, the middle sliding table does not move, and the sliding tables on both sides continue to move a small distance to form overturning, so that the reinforcing mesh 12 can spring back with size meeting requirements after removing the arc bending mechanism, and a curved reinforcing mesh can be formed; Step S27: Connect and fix two cambered reinforcing meshes to form an annular reinforcing mesh. Step S3 specified in another preferred embodiment of the invention, i.e., connect and fix other annular meshes into make annular components, specifically comprises the followings: S31: Install the annular meshes of inner side first, then lift other annular meshes and place them in designated position. After adjusting and confinning positions, place the next annular mesh until all annular meshes of the same section are placed; S34: Thread drag hook bars through meshes after they are completely made into annular meshes to construct a complete reinforcement component. Although the embodiment of the invention has been disclosed as above, it is not limited to the application listed in the specification and implementation mode. It can be fully applied to various fields suitable for the invention. For those who are familiar with the field, additional modifications can be easily realized. So, the invention is not limited to specific details and illustrations shown and described here without departing from the general concept defined by the claim and the equivalent range.

Claims

1. A forming process of oversize annular reinforcing mesh component comprising the following steps:step SI: preparing flat reinforcing meshes;step S2: bending flat reinforcing meshes into a semicircle and connecting and fixing two cambered reinforcing meshes to form an annular reinforcing mesh;step S3: connecting and fixing more annular reinforcing meshes into annular components;wherein in step S2, an arc bending device is used to bend the reinforcing meshes into a semicircle, the arc bending device comprising:a pedestal of semi-circular type having an arc surface; anda plurality of arc bending mechanisms distributed at intervals along the arc surface of the pedestal;wherein each arc bending mechanism comprises:a steel bar grasping mechanism;a mesh strut, connected at one end to the steel bar grasping mechanism for grasping the reinforcing mesh to be bent, wherein the other end is hinged on the rotary table and is rotatable around a hinge point between the rotary table and the mesh strut to adjust an angle; anda power mechanism, wherein the steel bar grasping mechanism is connected to the power mechanism and is capable of extension andretraction as driven by the power mechanism, so that the reinforcing mesh can be bent and deformed.

2. The forming process of oversize annular reinforcing mesh component according to claim 1, wherein step SI comprises the following steps:Sil: connecting stirrups into through-length steel bars by means of flash butt welding, cutting them based on required length and then delivering them onto a stirrup preparation table;S12: pulling the through-length steel bars on the stirrup preparation table to a plane bending mechanism with a plurality of stirrup slots that are feasible for lateral movement; and drive the stirrups to move and complete plane bending;S13: welding main reinforcements on the stirrups, wherein once all main reinforcements are welded the production of reinforcing mesh on a single plane is completed;S14: after the production of reinforcing mesh on planes, fixing solid toolings on meshes to prevent mesh deformation during transfer and storage;S15: repeating S11-S14 until reinforcing meshes on all planes are produced.

3. The forming process of oversize annular reinforcing mesh component according to claim 1, wherein the rotary table is provided with a fixed support and a telescopic rod, wherein one end of the telescopic rod is connected to the mesh strut, and the other end is connected to the fixed support, so as to control the rotation angle of the mesh strut by adjusting the length of the telescopic rod, wherein the telescopic rod, the rotary table and the fixed support, and the steel bar grasping mechanism are respectively located on both sides of the mesh strut.

4. The forming process of oversize annular reinforcing mesh component according to claim 3, wherein the rotary table is arranged on a sliding table that can slide along the track, the sliding table is located on one side of the mesh strut, and on the same side with the telescopic rod, rotary table and fixed support.

5. The forming process of oversize annular reinforcing mesh component according to claim 3, whereinstep S2 further comprises the following steps:S21: temporarily fixing reinforcing meshes, by using the plurality of arc bending mechanisms to pull the reinforcing mesh, resulting in preliminary deformation;S22: grasping reinforcing meshes with the steel bar grasping mechanism, starting the power mechanism to drive the steel bar grasping mechanism to retract and drive reinforcing meshes to move to both sides, so as to deform reinforcing meshes gradually;S23: with the gradual retraction of steel bar grasping mechanism, the reinforcing meshes gradually getting close to the mesh strut and cling to the mesh strut, wherein once tightly clinging to the mesh strut, the reinforcing meshes will hold the steel bar tightly on them;S24: adjusting the tilt disclosure of the mesh strut by adjusting the length of the telescopic rod according to the bending parameters related to reinforcing meshes, so that the top and bottom sizes can be different after bending reinforcing meshes;S25: according to the designed arc dimension of reinforcing meshes, moving all sliding tables in die arc bending mechanism in the same direction as driven by a hydraulic cylinder.

6. The forming process of oversize annular reinforcing mesh component according to claim 5, wherein step S2 also comprises the following steps:step S26: when the arc of the reinforcing mesh reaches the designed dimension, wherein the size of reinforcing meshes should be ensured to meet design requirements so as to form curved reinforcing mesh afterremoving the arc bending mechanism;step S27: connecting and fixing two cambered reinforcing meshes to form an annular reinforcing mesh.

7. The forming process of oversize annular reinforcing mesh component according to claim 3, wherein step S2 comprises the following steps before bending the flat reinforcing meshes with the arc bending device and performing step S21 as defined in claim 5:S20: temporarily fixing the middle of reinforcing mesh on the mesh support composed of two boards hinged on one side and a hydraulic rod between them, wherein the fixing end of the hydraulic rod is connected with one of the boards and its telescopic end is connected to the other board, then folding the mesh strut and placing the board connected to the fixing end of the hydraulic rod on the ground;wherein the hydraulic rod can be extended so that the board connected to the telescopic end of the hydraulic rod rotates along the other board until the board connected to the telescopic end of the hydraulic rod is perpendicular to the ground.

8. The forming process of oversize annular reinforcing mesh component according to claim 1, wherein step 3 specifically includes the following steps:S31: installing the annular meshes of an inner side first, then lifting other annular meshes and placing them in designated position, after adjusting and confinning positions, placing the next annular mesh until all annular meshes of the same section are placed;S34: threading drag hook bars through meshes after they are completely made into annular meshes to construct a complete reinforcement component.

Images