Rebar assembly system

Abstract

To provide a rebar assembly system capable of assembling rebars arranged in two vertically stacked stages.SOLUTION: The rebar assembly system places loop rebars 19, places a second rebar 21 intersecting a lower-stage portion 23 of the loop rebars 19, places a guide portion 29, and places a third rebar 22 on the guide portion 29. The rebar assembly system moves the guide portion 29 upward to bring the third rebar 22 into contact with an upper-stage portion 25 of the loop rebars 19. The rebar assembly system places a first rebar 20 on the third rebar 22.SELECTED DRAWING: Figure 7

Description

[Technical Field]

[0001] The present invention relates to a reinforcing bar assembly system and assembly method for assembling a reinforcing bar structure including reinforcing bars arranged in two layers, one above the other. [Background technology]

[0002] Conventionally, the assembly work of reinforcing bars, in which reinforcing bars are placed in predetermined positions and tied together, has been performed manually by workers. Various means have been proposed to improve the efficiency of such assembly work of reinforcing bars.

[0003] For example, Patent Document 1 discloses a reinforcing bar assembly system that uses a robot arm or the like to automatically supply, arrange, and bind reinforcing bars. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2021-049567 Summary of the Invention [Problem to be solved by the invention]

[0005] The rebar assembly system described in Patent Document 1 can only automatically assemble one layer of rebar. Therefore, to assemble rebars arranged in two layers, one above the other, it was necessary to automatically assemble the first layer of rebars, then transport it to an auxiliary work area, where a worker would manually insert auxiliary rebars, move it back to the automatic assembly area, and automatically assemble the second layer.

[0006] Conventional precast concrete elements containing rebar arranged in two layers, one above the other, sometimes contain loop rebar exposed from the concrete to form joints with the rebar of other precast concrete elements. Loop rebar is formed by combining two J-shaped rebars to form a ring. Assembly of rebar containing such loop rebar is performed by placing the J-shaped rebar located below, then placing a rebar perpendicular to it, and then inserting the J-shaped rebar located above from the direction of its extension. However, inserting rebar from the side has been difficult in systems that automatically assemble rebar.

[0007] In view of the above background, an object of the present invention is to provide a reinforcing bar assembly system capable of assembling reinforcing bars arranged in two tiers, one above the other. [Means for solving the problem]

[0008] In order to solve the above problem, one aspect of the present invention is a reinforcing bar assembly system (1) for assembling reinforcing bars (3) arranged in two tiers, one above the other, comprising a reinforcing bar stand (11) for supporting the reinforcing bars (3), an upper reinforcing bar binding device (13) for binding the reinforcing bars (3) arranged in the upper tier, and a lower reinforcing bar binding device (15) for binding the reinforcing bars (3) arranged in the lower tier, wherein the reinforcing bar stand (11) includes a base (28) configured to support the reinforcing bars (3) including the portion to be arranged in the lower tier, and a guide part (29) that can be arranged in a placement position above the base (28) to support the reinforcing bars (3) to be arranged in the upper tier and that is configured to be displaceable upward from the placement position.

[0009] According to this aspect, after placing the reinforcing bars on the guide section, the guide section can be displaced upward to bring the reinforcing bars placed above it and the reinforcing bars placed on the guide section into contact with each other so that they can be bound together. This makes it possible to assemble reinforcing bars arranged in two stages.

[0010] In the above aspect, the robot arm main body (14) may further include a robot arm main body (14) to which the upper reinforcement tying device (13) can be attached, and the upper reinforcement tying device (13) may include a three-dimensional camera (35) configured to be able to photograph the intersection of the reinforcing bars (3) to be tied, and the robot arm main body (14) may be configured to move the upper reinforcement tying device (13) to the position where the reinforcing bars (3) should be tied according to the design, and to correct the position where the upper reinforcement tying device (13) should be placed to tie the reinforcing bars (3) based on the image of the reinforcing bars (3) photographed by the three-dimensional camera (35).

[0011] According to this aspect, the deviation of the actual position of the reinforcing bar from the designed position of the reinforcing bar can be grasped based on the image captured by the 3D camera, and the upper reinforcing bar binding device can be moved to accommodate this deviation, thereby binding the reinforcing bar.

[0012] One aspect of the present invention is a method for assembling reinforcing bars (3) arranged in two upper and lower tiers, comprising a reinforcing bar arrangement step in which the reinforcing bars (3) are arranged on the reinforcing bar stand (11) by a gripping device (12) that can be moved above the reinforcing bar stand (11) by a robot arm body (14), a lower tier binding step in which the reinforcing bars (3) located in the lower tier are bound by a lower reinforcing bar binding device (15) that can be moved below the reinforcing bars (3) arranged on the reinforcing bar stand (11), and a lower tier binding step in which the reinforcing bars (3) located in the upper tier are bound by an upper reinforcing bar binding device (13) that can be moved above the reinforcing bar stand (11) by the robot arm body (14). and an upper bundling step for bundling the reinforcing bar (3) that is to be installed in the reinforcing bar (3), wherein the reinforcing bar (3) comprises a loop reinforcing bar (19) having a lower portion (23), curved portions (24) that extend upward in a semicircular shape so as to bulge outward from both ends of the lower portion (23) in the direction of extension, and a pair of upper portion (25) that extend from the upper end of the curved portion (24) so ​​that their tip portions approach each other and define an opening (26) between the tip portions, a first reinforcing bar (20) that is placed on top of the pair of upper portion (25) so as to close the opening of the loop reinforcing bar (19), and a second reinforcing bar (20) that crosses the lower portion (23) of the loop reinforcing bar (19). The reinforcing bar frame (11) includes a second reinforcing bar (21) that is tied across the upper portion (25) of the loop reinforcing bar (19) and / or a third reinforcing bar (22) that is tied across the upper portion (25) of the loop reinforcing bar (19) and / or the first reinforcing bar (20), and the reinforcing bar frame (11) includes a base portion (28) configured to support the lower portion (23) of the loop reinforcing bar (19) and a guide portion (29) configured to support the third reinforcing bar (22), and the reinforcing bar arrangement step includes a step of placing the loop reinforcing bar (19) on the base portion (28) of the reinforcing bar frame (11) and a step of placing the second reinforcing bar (21) on the lower portion (23) of the loop reinforcing bar (19). the step of placing the third reinforcing bar (22) on the guide portion (29); the step of moving the guide portion (29) upward so as to press the third reinforcing bar (22) against the upper portion (25) of the loop reinforcing bar (19); the step of placing the first reinforcing bar (20) on the third reinforcing bar (22) so that both ends of the first reinforcing bar (20) overlap the pair of upper portions (25) of the loop reinforcing bar (19).

[0013] According to this embodiment, after the loop reinforcement is installed, the second and third reinforcement bars can be moved from top to bottom to be placed in the desired position, and two tiers of reinforcement bars, upper and lower, can be assembled.

[0014] In the above aspect, the upper binding step may include the steps of moving the upper reinforcing bar binding device (13) to the vicinity of the designed binding position, photographing the reinforcing bar (3) to be bound with a three-dimensional camera (35), calculating the deviation of the actual position of the reinforcing bar (3) to be bound from the designed position based on the photographed image, and if the deviation exceeds the allowable range, moving the upper reinforcing bar binding device (35) to a position where the reinforcing bar (3) to be bound can be bound.

[0015] Since loop reinforcement bars with curved sections are prone to variations in shape, the position of the upper section relative to the lower section may deviate from the design. According to this aspect, the 3D camera can be used to determine the deviation of the actual position of the rebar from the designed position of the rebar, and by moving the upper reinforcement binding device according to this deviation, the rebar placed in the upper section can be bound reliably. [Effects of the Invention]

[0016] According to the above aspect, it is possible to provide a reinforcing bar assembly system capable of assembling reinforcing bars arranged in two tiers, one above the other. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a schematic perspective view showing a factory in which a reinforcing bar assembly system according to an embodiment is installed. [Figure 2] FIG. 1 is a perspective view showing a reinforcing bar assembly system according to an embodiment; [Figure 3] FIG. 1 is a perspective view of a reinforced concrete member including a reinforcing bar assembled by a reinforcing bar assembly system according to an embodiment; [Figure 4]Reinforcement diagram of a reinforced concrete member including reinforcing bars assembled by the reinforcing bar assembly system according to the embodiment [Figure 5] 1 is a front view showing a gripping device of a reinforcing bar assembly system according to an embodiment; [Figure 6] A front view showing an upper reinforcing bar binding machine of a reinforcing bar assembly system according to an embodiment. [Figure 7] FIG. 1 is an explanatory diagram showing a reinforcing bar arrangement procedure using a reinforcing bar assembly system according to an embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0019] FIG. 1 is a schematic perspective view showing a factory 2 in which a reinforcing bar assembly system 1 is installed. The factory 2 is provided with a material temporary storage area 4 for temporarily storing materials such as reinforcing bars 3, a reinforcing bar assembly area 5 for assembling the reinforcing bars 3, and an assembled reinforcing bar temporary storage area 6 for temporarily storing assembled reinforcing bars 3. Materials and the like are transported from the material temporary storage area 4 to the reinforcing bar assembly area 5, and from the reinforcing bar assembly area 5 to the assembled reinforcing bar temporary storage area 6, using a gantry crane 7.

[0020] FIG. 2 is a perspective view showing a rebar assembly system 1 arranged in a rebar assembly area 5. The rebar assembly system 1 includes a plurality of rebar feeders 8 that store and supply rebars 3 before assembly, an individual rebar conveyor 9 that transports the rebars 3 supplied from the rebar feeders 8, an assembled rebar conveyor 10, a rebar stand 11 supported by the assembled rebar conveyor 10, a gripping device 12 that can grip the rebars 3, an upper rebar tying device 13 that ties the rebars 3 arranged in the upper tier (see FIG. 6), a robot arm main body 14 whose base end is fixed and whose free end can selectively attach the gripping device 12 or the upper rebar tying device 13, and a lower rebar tying device 15 that ties the rebars 3 arranged in the lower tier (the rebar feeders 8 and the individual rebar conveyor 9 on the left side of FIG. 2 are not shown). A robot arm 16 is configured by attaching the gripping device 12 or the upper rebar tying device 13 to the robot arm main body 14. When the robot arm 16 is equipped with the gripping device 12, it grasps the reinforcing bars 3 transported by the individual reinforcing bar conveyor 9 and places them on the reinforcing bar stand 11 on the assembled reinforcing bar conveyor 10, and when the upper reinforcing bar binding device 13 is equipped with the robot arm 16, it binds the intersecting parts of the reinforcing bars 3 arranged on the upper level and the parts that form lap joints.

[0021] FIG. 3 shows a precast concrete member 17 including reinforcing bars 3 assembled by the reinforcing bar assembly system 1 (see FIG. 2), and FIG. 4 shows a reinforcing bar arrangement diagram. The precast concrete member 17 is a member from which a large number of identical structures are manufactured, and is a member that constitutes, for example, a concrete floor slab. The concrete portion 18 of the precast concrete member 17 has a roughly rectangular outer contour in plan view. The reinforcing bars 3 are arranged in two tiers, upper and lower, and the reinforcing bars 3 arranged in the upper tier and the reinforcing bars 3 arranged in the lower tier are arranged so that they roughly overlap when viewed from the top and bottom, excluding the placement of joints. Both sides of the loop reinforcement 19 extending in the short direction of the precast concrete member 17 are exposed from the concrete portion 18. The precast concrete member 17 may be a prestressed concrete structure.

[0022] As shown in Figures 4 and 7, the reinforcing bars 3 include a plurality of loop reinforcing bars 19 arranged to extend in the short direction, a plurality of first reinforcing bars 20 arranged in the upper row and extending in the short direction, a plurality of second reinforcing bars 21 arranged in the lower row and extending in the longitudinal direction of the precast concrete member 17, and a plurality of third reinforcing bars 22 arranged in the upper row and extending in the longitudinal direction.

[0023] The loop reinforcement 19 has a lower section 23 extending in the short direction, curved sections 24 extending upward in a semicircular shape from both ends of the lower section 23 so as to bulge outward in the short direction, and a pair of upper sections 25 extending in the short direction from the upper end of the curved section 24 so that their tips approach each other. An opening 26 is defined between the tips of the pair of upper sections 25. In other words, the loop reinforcement 19 has a ring-like shape similar to that of an athletics track, with the opening 26 formed by cutting out a portion of the upper straight section. The first reinforcing bar 20 is positioned so that it covers the opening 26 of the loop reinforcement 19 and its both ends form a lap joint with the pair of upper sections 25. The second reinforcing bar 21 and the third reinforcing bar 22 are positioned inside the ring-like shape formed by the loop reinforcement 19 and the first reinforcing bar 20. Preferably, the loop reinforcement 19 and the first reinforcing bar 20 are each composed of a single steel bar. Each of the second reinforcing bar 21 and the third reinforcing bar 22 may be formed of a single steel rod member, or may be formed by connecting a plurality of steel rod members with lap joints. It is preferable that one of the second reinforcing bar 21 and the third reinforcing bar 22 has a hook shape at both ends, bent at 90° toward the other of the second reinforcing bar 21 and the third reinforcing bar 22.

[0024] Refer to Figure 2. A plurality of reinforcing bar feeders 8 are provided, and reinforcing bars 3 are stored in different reinforcing bar feeders 8 according to their shape (length). The reinforcing bar feeder 8 includes a storage section 27 that stores the reinforcing bars 3, and a supply reinforcing bar gripping device (not shown) that removes the reinforcing bars 3 from the storage section 27 and moves them to the individual reinforcing bar conveyor 9. The supply reinforcing bar gripping device (not shown) has a structure similar to that of the gripping device 12, and is movable between above the storage section 27 and above the individual reinforcing bar conveyor 9.

[0025] The conveyor for individual rebars 9 and the conveyor for assembled rebars 10 are, for example, roller conveyors that move the objects placed on them in their extension direction. The extension direction and width direction of the conveyor for individual rebars 9 and the conveyor for assembled rebars 10 correspond to the longitudinal direction and transverse direction of the rebars 3 being assembled. Hereinafter, the extension direction and width direction of the conveyor for individual rebars 9 and the conveyor for assembled rebars 10 will be referred to as the longitudinal direction and transverse direction. The conveyor for individual rebars 9 transports the rebars 3 supplied from the rebar supply machine 8 to a position where they can be grasped by the robot arm 16 with the gripping device 12 attached. The conveyor for assembled rebars 10 is linked to the robot arm 16 during the assembly of the rebars 3. An individual rebar stand 47 on which the individual rebars 3 are placed is placed on the conveyor for individual rebars 9.

[0026] As shown in Figures 2 and 7, the reinforcing bar stand 11 includes a base 28 supported by the assembled reinforcing bar conveyor 10, a guide 29, and an actuator 30 for vertically displacing the guide 29. The base 28 has a rectangular frame shape in plan view, and its upper edge supports the loop reinforcing bars 19 and the second reinforcing bars 21. When each of the longitudinally arranged second reinforcing bars 21 is formed by lap joints of multiple steel rods, the base 28 has a portion (not shown) extending in the transverse direction connected to the middle of two longitudinally extending side edges 28a of the frame shape so that each steel rod is supported at two or more locations. The guide 29 is made of multiple rod- or plate-shaped members extending in the transverse direction and spaced apart from each other in the longitudinal direction, and supports the third reinforcing bars 22. The upper edges of the base 28 and the guide 29 are provided with grooves 31 for receiving the reinforcing bars 3 to be supported. The actuator 30 is connected to the base 28 by a connecting member 48 and includes, for example, an electric cylinder. A protrusion 49 is provided on the upper edge of the connecting member 48, protruding upward outward in the lateral direction from the groove 31 in order to restrict movement of the first reinforcing bar 20 in the longitudinal direction. The second reinforcing bar 21 may be supported on the base 28 via the lower portion 23 of the loop reinforcing bar 19. In this case, the second reinforcing bar 21 does not abut against the bottom of the groove 31, and its movement in the lateral direction is restricted by the side edges of the groove 31.

[0027] 5 is a front view showing the gripping device 12. The gripping device 12 includes a mounting portion 32 attached to the robot arm body 14, a clamp 33 that grips the rebar 3, and a connecting portion 34 that connects the mounting portion 32 and the clamp 33 to each other.

[0028] See Figure 2. Two robot arms 16 are installed at positions offset from each other in the longitudinal direction. Two gripping devices 12 and two upper reinforcing bar binding devices 13 (see Figure 6) are provided. A frame 36 (see Figure 1) is erected on the floor of the factory 2, and the ceiling of the frame 36 partially covers the upper part of the assembled reinforcing bar conveyor 10. The base end of the robot arm main body 14 is fixed to the ceiling of the frame 36. In addition, the robot arm main body 14 is equipped with multiple joints so that the gripping device 12 can move the reinforcing bar 3, and is rotatable around a predetermined axis at its free end.

[0029] As shown in Figure 2, the robot arm 16 with the gripping device 12 attached is controlled to automatically grip the reinforcing bar 3 transported by the individual reinforcing bar conveyor 9 and place it on a reinforcing bar stand 11 supported on the assembled reinforcing bar conveyor 10. At this time, the assembled reinforcing bar conveyor 10 is linked to the robot arm 16 to reduce the range of movement of the robot arm 16.

[0030] FIG. 6 is a front view of the upper reinforcing bar binding device 13. As shown in FIG. 6, the upper reinforcing bar binding device 13 includes a mounting portion 37 attached to the robot arm body 14, a binding machine body 38, a fixing portion 39 that fixes the binding machine body 38 to the mounting portion 37, and a 3D camera 35. The binding machine body 38 can be a commercially available reinforcing bar binding machine that is carried by a worker. The binding machine body 38 includes a grip 40 fixed to the fixing portion 39, a trigger 41, and a tip binding portion 43 that wraps and twists the wire around the reinforcing bar 3 by moving a lever 42 to pull the trigger 41 or by electrically inputting a trigger signal to the binding machine body 38.

[0031] The robot arm 16 with the upper reinforcing bar tying device 13 attached is controlled to automatically tie the portion of the reinforcing bars 3 placed in the upper tier on the assembled reinforcing bar conveyor 10. That is, after inserting the tip tying part 43 of the binding machine main body 38 from above into the portion of the reinforcing bars 3 to be tied, the trigger 41 is pulled or a trigger ON signal is input repeatedly. While the robot arm 16 is arranging the reinforcing bars and tying the reinforcing bars 3 placed in the upper tier, the assembled reinforcing bar conveyor 10 carrying the reinforcing bar stand 11 moves in conjunction with the robot arm 16 to reduce the range of movement of the robot arm 16.

[0032] See FIG. 2. The reinforcing bar assembly system 1 includes a first rail 44 fixed to the floor of the factory 2 and extending in the transverse direction, and a second rail 45 supported by the first rail 44 and extending in the longitudinal direction, movable in the transverse direction. The first rail 44 and the second rail 45 are located below the reinforcing bar stand 11. The lower reinforcing bar binding device 15 includes a lower portion 46 supported by the second rail 45 and movable in the longitudinal direction, and a binding machine main body 38 (see FIG. 6) supported by the lower portion 46 and rotatable about a vertical axis and movable in the vertical direction. The binding machine main body 38 is controlled to insert a tip binding part 43 (see FIG. 6) from below into the portion of the reinforcing bar 3 to be bound, arranged in the lower tier, and bind that portion. The length of the second rail 45 extending in the longitudinal direction may be shorter than the longitudinal length of the reinforcing bar 3, because the reinforcing bar 3 can be moved in the longitudinal direction by the assembling reinforcing bar conveyor 10. Instead of the first rail 44 and / or the second rail 45, the lower portion 46 may have an arm structure having a joint, and the binding machine main body 38 may be moved in the lateral direction by the lower portion 46.

[0033] It is preferable to install a safety fence (not shown) around the periphery of the reinforcing bar assembly system 1 and place a sensor at a door in the safety fence to detect people entering or exiting. The movements of the reinforcing bar feeder 8, the individual reinforcing bar conveyor 9, the assembled reinforcing bar conveyor 10, the lower reinforcing bar binding device 15, the robot arm 16, and the guide part 29 and actuator 30 of the reinforcing bar stand 11 are controlled by a control device (not shown).

[0034] The procedure for assembling the reinforcing bars 3 will be described with reference to Figures 2 and 7. First, the reinforcing bars 3 transported by the gantry crane 7 to the reinforcing bar assembling area 5 are placed by a worker on reinforcing bar supply machines 8, which differ depending on their shapes. The worker then activates the reinforcing bar assembling system 1. The reinforcing bar supply machine 8 places the reinforcing bar 3 to be assembled on an individual reinforcing bar stand 47 on the individual reinforcing bar conveyor 9, and the individual reinforcing bar conveyor 9 transports the reinforcing bar 3 to a position where it can be grasped by a robot arm 16 to which a grasping device 12 is attached.

[0035] A gripping device 12 is attached to each of the two robot arm bodies 14. The two robot arms 16 perform rebar placement work. The robot arm 16, to which the gripping device 12 is attached, first places a loop rebar 19 on the base 28 of a rebar stand 11 supported on a conveyor 10 for assembled rebars. The loop rebar 19 extends in the short direction and is placed so that the upper section 25 is located above the lower section 23 (FIG. 7(A)). After placing all of the loop rebars 19, the robot arm 16 places a second rebar 21 on the base 28 of the rebar stand 11 or the lower section 23 of the loop rebar 19 (FIG. 7(B)). At this time, the robot arm 16 inserts the second rebar 21, which extends in the long direction, into the loop rebar 19 from above so that it passes through the opening 26 of the loop rebar 19, and moves it in the short direction as necessary to place it in the desired position.

[0036] After all the second reinforcing bars 21 have been placed, the lower reinforcing bar binding device 15 starts binding the intersections between the lower sections 23 of the loop reinforcing bars 19 placed in the lower tier and the second reinforcing bars 21, and the sections that form the lap joints in the second reinforcing bars 21. In parallel with the binding work of the lower reinforcing bar binding device 15 on the reinforcing bars 3 placed in the lower tier, the following work is carried out.

[0037] The reinforcing bar assembly system 1 inserts the guide portion 29 of the reinforcing bar frame 11 from above into a placement position above the lower portion 23 of the loop reinforcing bar 19 and the second reinforcing bar 21 and below the upper portion 25 of the loop reinforcing bar 19, and supports it with the actuator 30. The placement position is a position where the upper edge of the guide portion 29 is separated from the lower edge of the upper portion 25 of the loop reinforcing bar 19 by a distance longer than the diameter of the third reinforcing bar 22. The robot arm 16 places the third reinforcing bar 22 into the guide portion 29 of the reinforcing bar frame 11 ( FIG. 7(C) ). At this time, the robot arm 16 inserts the third reinforcing bar 22, which extends in the longitudinal direction, from above into the loop reinforcing bar 19 so that it passes through the opening 26 of the loop reinforcing bar 19, similar to the second reinforcing bar 21, and moves it in the transverse direction as necessary to place it in a predetermined position.

[0038] After all the third reinforcing bars 22 have been placed, the actuator 30 moves the guide part 29 upward from the placement position, and places the third reinforcing bars 22 in an abutment position where they abut against the upper part 25 of the loop reinforcing bars 19. The robot arm 16 places the first reinforcing bar 20 on the third reinforcing bar 22 so that it closes the opening 26 and its both ends form a lap joint with the upper part 25 of the loop reinforcing bars 19 (FIG. 7(D)).

[0039] Next, the robot arm body 14 removes the gripping device 12 and attaches the upper reinforcing bar tying device 13 to its free end. The robot arm 16 equipped with the upper reinforcing bar tying device 13 ties the upper section 25 of the loop reinforcing bar 19 arranged in the upper section and / or the intersection between the first reinforcing bar 20 and the third reinforcing bar 22, or the portion of the third reinforcing bar 22 that forms a lap splice. At this time, the reinforcing bar assembly system 1 moves the upper reinforcing bar tying device 13 to the design position where the tying work will be performed, and then photographs the reinforcing bar 3 to be tying with the 3D camera 35. If the deviation between the actual position of the reinforcing bar 3 calculated based on the photographed image and the design position of the reinforcing bar 3 exceeds the tolerance range, the upper reinforcing bar tying device 13 moves to a position where it can tie the reinforcing bar 3 in accordance with the actual position of the reinforcing bar 3, and then tying the reinforcing bar 3.

[0040] Once the binding of both the upper and lower reinforcing bars 3 is complete, the assembled reinforcing bars 3 are transported to the assembled reinforcing bar temporary storage area 6 by the assembled reinforcing bar conveyor 10 and the gantry crane 7. If necessary, additional reinforcing bar arrangement and binding work may be performed by workers.

[0041] The effects of the above embodiment will be described.

[0042] A robot arm main body 14 capable of attaching an upper reinforcing bar tying device 13 is arranged above the reinforcing bar 3 being assembled, and a lower reinforcing bar tying device 15 is arranged below, so that the tying work of the reinforcing bars 3 arranged in the upper and lower tiers can be performed in parallel. This improves work efficiency and also increases the automation rate of assembling the reinforcing bars 3 (the automation rate of the reinforcing bar assembling system 1 described in Patent Document 1 is approximately 75% and the number of workers is six, while the automation rate of the reinforcing bar assembling system 1 according to this embodiment is approximately 85% and the number of workers is two).

[0043] The work of tying the reinforcing bars 3 placed in the lower tier using the lower reinforcing bar binding device 15 can begin before the placement of the third reinforcing bar 22 and the first reinforcing bar 20, but the work of tying the reinforcing bars 3 placed in the upper tier using the upper reinforcing bar binding device 13 must be performed after the placement of the third reinforcing bar 22 and the first reinforcing bar 20. By using one lower reinforcing bar binding device 15 to perform the work that can be started first and two upper reinforcing bar binding devices 13 and robot arm bodies 14 to operate the upper reinforcing bar binding device 13 to perform the work that can be started later, it is possible to suppress increases in equipment costs while reducing the standby time of the upper reinforcing bar binding device 13, robot arm body 14, and lower reinforcing bar binding device 15, thereby enabling efficient assembly of the reinforcing bars 3. Note that the number of upper reinforcing bar binding devices 13 and robot arm bodies 14 may be three or more, and the number of lower reinforcing bar binding devices 15 may be two or more but fewer than the number of upper reinforcing bar binding devices 13 and robot arm bodies 14. In this case, the same effect as above can be obtained.

[0044] Since the lower bar binding device 15 is supported on rails 45, the coordinates of the lower bar binding device 15 can be clearly grasped compared to when the lower bar binding device 15 is moved across the floor of the factory 2 using wheels or the like.

[0045] The loop reinforcement 19 having the curved portion 24 is formed by bending a steel rod that extends in a straight line, but at this time, errors are likely to occur in the shape of the curved portion 24, causing variations in the position of the upper portion 25 relative to the lower portion 23. By using the guide portion 29, even if the position of the upper portion 25 varies, the third rebar 22 can be brought into contact with the upper portion 25 of the loop reinforcement 19, and the intersection of the two can be bound together.

[0046] By using the 3D camera 35 to photograph the rebar 3 to be tied, the rebar assembly system 1 can grasp the deviation of the actual position of the rebar 3 from the designed position of the rebar 3, and can move the upper rebar binding device 13 according to that deviation.

[0047] In the reinforcing bar assembly system 1 configured in this manner, the base end of the robot arm 16 is fixed and immovable relative to the factory 2, so the coordinates of the gripping device 12 and upper reinforcing bar binding device 13 attached to the robot arm body 14 can be clearly grasped. Therefore, the reinforcing bar assembly system 1 can accurately place and bind the reinforcing bars 3 to be assembled. In addition, by placing the reinforcing bars 3 in the grooves 31 of the reinforcing bar stand 11, the accuracy of the position of the placed reinforcing bars 3 is improved.

[0048] Since the assembled rebar conveyor 10 is linked to the robot arm 16, rebars 3 that are outside the operating range of the robot arm 16 can also be placed or bound.

[0049] The rebar feeder 8 automatically supplies the rebars 3, improving work efficiency. Even if different rebar feeders 8 are used for different shapes and lengths of the rebars 3, the individual rebar conveyor 9 transports the rebars 3 supplied by the rebar feeders 8, allowing the gripping device 12 to grip the rebars 3 without increasing the range of motion of the robot arm 16.

[0050] Although the specific embodiments have been described above, the present invention is not limited to the above embodiments and can be widely modified and implemented. The present invention can also be applied to the assembly of rebars for cast-in-place concrete. The angle at which the second and third rebars intersect with the loop rebars and first rebars in a plan view may be an angle other than 90°. The second and third rebars may extend in the short direction, and the loop rebars and first rebars may extend in the long direction. If the assembling rebar conveyor 10 is not moved while the guide unit is in use, the actuator that displaces the guide unit may be supported on the factory floor or the like instead of the base of the rebar frame. The extension direction of the rail may intersect with the long direction at an angle other than perpendicular. [Explanation of symbols]

[0051] 1: Rebar assembly system 3: Reinforced concrete 10: Conveyor for assembled rebar 11: Reinforced concrete frame 12: Gripping device 13: Upper muscle binding device 14: Robot arm body 15:Lower muscle binding device 19: Loop muscle 20: First rebar 21: Second rebar 22: Third rebar 23: Lower section 24: Curved section 25: Upper section 26:Aperture 28: Base 29: Guide section 35: 3D camera 44: First Rail

Claims

1. A rebar assembly system for assembling rebars arranged in two levels, one above the other, A reinforcing bar stand for supporting the reinforcing bar, the reinforcing bar stand including a base configured to support the reinforcing bar including a portion to be placed in a lower tier, and a guide portion that can be placed in a placement position above the base to support the reinforcing bar to be placed in an upper tier and is configured to be displaceable upward from the placement position; An upper reinforcing bar binding device that binds the reinforcing bars arranged in the upper stage; A lower reinforcing bar binding device that binds the reinforcing bars arranged in the lower stage; A robot arm body, a gripping device attached to the robot arm body, capable of gripping the reinforcing bar and moving above the reinforcing bar stand; a control device that controls the guide unit, the robot arm body, the gripping device, the upper reinforcing bar binding device, and the lower reinforcing bar binding device so as to assemble the reinforcing bars; Equipped with The reinforcing bar includes a loop reinforcing bar having a lower portion, curved portions extending upward in a semicircular shape from both ends of the lower portion so as to bulge outward in the direction of extension, and a pair of upper reinforcing bars extending from the upper end of the curved portion so that their tips approach each other and defining an opening between the tips; a first reinforcing bar arranged on top of the pair of upper reinforcing bars so as to close the opening of the loop reinforcing bar; a second reinforcing bar tied across the lower reinforcing bar of the loop reinforcing bar; and a third reinforcing bar tied across the upper reinforcing bar of the loop reinforcing bar and / or the first reinforcing bar. The control device is a reinforcing bar assembly system configured to move the guide portion upward so as to press the third reinforcing bar supported by the guide portion against the upper portion of the loop reinforcing bar, which is supported by the base and does not move.

2. The robot arm body is capable of mounting the upper muscle binding device, The upper reinforcing bar binding device includes a three-dimensional camera configured to be able to photograph the intersections of the reinforcing bars to be bound, The rebar assembly system described in claim 1, wherein the robot arm body is configured to move the upper rebar binding device to a position where the rebar should be tied according to the design, and to correct the position where the upper rebar binding device should be placed to tie the rebar based on an image of the rebar taken by the 3D camera.

3. The control device further The loop reinforcement is placed on the base of the reinforcing bar frame, The second reinforcing bar is placed on the lower portion of the loop reinforcing bar, The guide portion is disposed above the lower portion of the loop muscle and below the upper portion of the loop muscle, The third reinforcing bar is placed on the guide portion, The reinforcing bar assembly system of claim 1, configured to place the first reinforcing bar on the third reinforcing bar so that both ends of the first reinforcing bar overlap the pair of upper portions of the loop reinforcing bar.

4. A method for assembling reinforcing bars arranged in two layers, one above the other, a reinforcing bar arrangement step in which the reinforcing bar is arranged on the reinforcing bar stand by a gripping device that can be moved above the reinforcing bar stand by a robot arm body; a lower tier binding step in which the reinforcing bars located in the lower tier are bound by a lower reinforcing bar binding device that is movable relative to the reinforcing bar frame below the reinforcing bars arranged on the reinforcing bar frame; an upper tier binding step of binding the rebars located in the upper tier by an upper rebar binding device that can be moved above the rebar stand by the robot arm body; Equipped with The reinforcing bar includes a loop reinforcing bar having a lower portion, curved portions extending upward in a semicircular shape from both ends of the lower portion so as to bulge outward in the direction of extension, and a pair of upper reinforcing bars extending from the upper end of the curved portion so that their tips approach each other and defining an opening between the tips; a first reinforcing bar arranged on top of the pair of upper reinforcing bars so as to close the opening of the loop reinforcing bar; a second reinforcing bar tied across the lower reinforcing bar of the loop reinforcing bar; and a third reinforcing bar tied across the upper reinforcing bar of the loop reinforcing bar and / or the first reinforcing bar. The reinforcing bar stand includes a base portion configured to support the lower portion of the loop reinforcing bar and a guide portion configured to support the third reinforcing bar, The reinforcement step includes: placing the loop reinforcement on the base of the reinforcing bar frame; placing the second reinforcing bar on the lower portion of the loop reinforcing bar; a step of disposing the guide portion above the lower portion of the loop reinforcement and below the upper portion of the loop reinforcement; placing the third reinforcing bar on the guide portion; Moving the guide portion upward so as to press the third reinforcing bar against the upper portion of the loop reinforcing bar; placing the first reinforcing bar on the third reinforcing bar so that both end portions of the first reinforcing bar overlap the pair of upper portions of the loop reinforcing bar; An assembly method comprising:

5. The upper bundling step includes: Moving the upper reinforcement binding device to a position near the designed binding position; Taking an image of the rebar to be bundled with a three-dimensional camera; A step of calculating a deviation of the actual position of the reinforcing bar to be tied from the design position based on the captured image, and if the deviation exceeds an allowable range, moving the upper reinforcing bar binding device to a position where the reinforcing bar to be tied can be tied. The assembly method of claim 4, comprising:

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