Reinforcement mesh quality inspection device and quality inspection method

Abstract

A quality inspection device and quality inspection method for a reinforcing steel mesh, wherein when the gate-type frame (1) is controlled to move in parallel, the first detection member (11) and the second detection member (12) scan the horizontal reinforcing bars (10) of the reinforcing steel mesh to acquire the position of the horizontal reinforcing bars (10), and when the detection assembly (2) is moved in parallel, the third detection member (21) scans the vertical reinforcing bars (20) of the reinforcing steel mesh to acquire the position of the vertical reinforcing bars (20), and the first detection member (11), second detection member (12), and third detection member The system includes the ability to determine the pass / fail status of the spacing between the horizontal bars (10), the spacing between the vertical bars (20), the protruding lengths of the horizontal bars (10) and vertical bars (20) relative to the reinforcing mesh, and the pass / fail status of the diagonal dimensions of the reinforcing mesh, based on the positions of the horizontal bars (10) and vertical bars (20) obtained by the protruding member (21); and the ability to determine the pass / fail status of the welding points between the horizontal bars (10) and vertical bars (20) using the welding point detection module (3), and further determine whether the welding quality of the reinforcing mesh meets the standard.

Description

Technical Field

[0001] This application claims the priority of a Chinese patent application filed with the Chinese Patent Office on August 10, 2023, with an application number of 202311002573.3, and the content of this application is incorporated herein by reference in its entirety.

[0002] This application relates to the technical field of quality inspection of steel bar meshes, for example, to a quality inspection device and a quality inspection method for steel bar meshes.

Background Art

[0003] In recent years, with the development of the mechanization and automation of construction equipment, an automatic welding robot is usually adopted for the manufacture of the steel bar mesh of the steel bar cage in the construction process of diaphragm walls. The steel bar mesh includes a plurality of horizontal bars and a plurality of vertical bars provided in parallel at intervals in a first direction, and a plurality of horizontal bars and a plurality of vertical bars are welded to each other. The welding quality of the steel bar mesh directly affects the hoisting safety of the steel bar cage and the quality of the diaphragm wall.

[0004] Currently, the quality inspection method of steel bar meshes mainly depends on manual labor. Generally, the quality inspection of steel bar meshes is carried out using visual inspection and measuring tools. Especially when visually inspecting each welding point of the steel bar mesh manually, it takes time and effort, and there is a possibility of false detection, and defective welding points cannot be accurately identified.

Summary of the Invention

[0005] In this application, there is provided a quality inspection device and a quality inspection method for a steel bar mesh, which can realize the automatic detection of the quality of the steel bar mesh, improve the quality inspection efficiency of the steel bar mesh, ensure the acceptance quality of the steel bar mesh, and realize the digital and intelligent quality inspection of the steel bar mesh.

[0006] In a first aspect, there is provided a quality inspection device for a steel bar mesh, wherein a plurality of steel bars of the steel bar mesh include a plurality of horizontal bars provided in parallel at intervals in a first direction, and a plurality of vertical bars provided in parallel at intervals in a second direction perpendicular to the first direction, and welding points are formed between the horizontal bars and the vertical bars by welding. The aforementioned reinforcing mesh quality inspection device is, A gate-type frame extending in the second direction and movable in the first direction, with a first detection member and a second detection member configured to detect the position of the transverse reinforcement bars at each end, A detection assembly is provided, which is mounted on the gate-type frame so as to be movable in a second direction and includes a third detection member configured to detect the position of the vertical reinforcement bars, A welding point detection module that collects images of the welding points and determines whether the welding points are pass or fail based on the images, A data processing module is configured to obtain, from the detection values ​​of the first detection member, the second detection member, and the third detection member, the spacing between adjacent horizontal reinforcements, the spacing between adjacent vertical reinforcements, the pass / fail status of the protrusion length of the horizontal reinforcements relative to the reinforcing mesh, the pass / fail status of the protrusion length of the vertical reinforcements relative to the reinforcing mesh, and the diagonal of the reinforcing mesh, and further configured to statistically calculate the failure rate of the welding points. Equipped with, We provide quality inspection equipment for reinforcing steel mesh.

[0007] In some embodiments, at least one of the first detection member, the second detection member, and the third detection member is equipped with a position sensor.

[0008] In the second aspect, a method for inspecting the quality of reinforcing steel using the above-described quality inspection device for reinforcing steel, The gate-type frame is controlled to move in the first direction, and during that period, the first detection member and the second detection member detect the position coordinates of the transverse bars, and the interval between adjacent transverse bars is obtained from at least one of the detection values ​​of the first detection member and the detection value of the second detection member. The detection assembly is controlled to move in the second direction, during which time the third detection member detects the position coordinates of the longitudinal reinforcement bars, and the interval between adjacent longitudinal reinforcement bars is obtained from the detected values ​​of the third detection member. The detection assembly is moved in parallel to control the third detection member to move by a first predetermined distance L1 away from the outermost part of the vertical reinforcement located at the end, and then the portal frame is moved in parallel in the first direction, and in response to the third detection member detecting a horizontal reinforcement, the protrusion length of the horizontal reinforcement relative to the reinforcing mesh is set to pass. The gate-shaped frame is moved in parallel to control the first detection member or the second detection member to move by a second predetermined distance L2 in the direction away from the outermost part of the transverse reinforcement located at the end, and then the detection assembly is moved in parallel in the second direction, and in response to the third detection member detecting the longitudinal reinforcement, the protrusion length of the longitudinal reinforcement relative to the reinforcing mesh is set to pass. The length of the first and second sides of the reinforcing bar mesh is determined based on the spacing between adjacent horizontal bars and the diameter of the horizontal bars, and the width of the third and fourth sides of the reinforcing bar mesh is determined based on the spacing between adjacent vertical bars and the diameter of the vertical bars. Based on the rectangle enclosed by the first, second, third, and fourth sides of the reinforcing mesh, the lengths of the two diagonals of the reinforcing mesh are determined, and it is determined whether the ratio of the two diagonals is within the error range. The welding point detection module is controlled to collect images of all the welding points and to detect whether the quality of all the welding points is acceptable or not. Record the number of unsatisfactory welds and statistically determine their proportion. including, This document provides a method for inspecting the quality of reinforcing steel mesh.

[0009] In some embodiments, the method further includes triggering a signal when the first detection member and the second detection member move to the outermost edge of the transverse bar, defining the coordinate differences when the first detection member and the second detection member trigger the signal twice (front and back) as H1 and H2, respectively, and determining whether the average value of H1 and H2 is within a specified range of the spacing of the transverse bar.

[0010] In some embodiments, the spacing of the longitudinal bars is determined by a method in which a signal is triggered when the third detection member moves to the outermost edge of the longitudinal bar, and the difference in coordinates when the third detection member triggers the signal twice (forward and backward) is defined as the spacing of the longitudinal bars.

[0011] In some embodiments, the detection assembly is moved in parallel to control the third detection member to move by a first predetermined distance L1 away from the outermost part of the vertical reinforcement located at the end, and then the portal frame is moved in parallel in the first direction. The detection assembly is controlled to move from the first end longitudinal reinforcement to the second end longitudinal reinforcement, and in response to the third detection member contacting the outermost edge of the second end longitudinal reinforcement, the detection assembly is controlled to move by a distance of L1 + Dz, and thereafter the portal frame is controlled to move in parallel in the first direction, where Dz is the diameter of the longitudinal reinforcement. Includes, The first end vertical reinforcement and the second end vertical reinforcement are the two vertical reinforcements at both ends of the reinforcing bar mesh, respectively.

[0012] In some embodiments, the portal frame is moved in parallel to control the first detection member or the second detection member to move by a second predetermined distance L2 in a direction away from the outermost part of the transverse bar located at the end, and then the detection assembly is moved in parallel in the second direction. The gate-shaped frame is controlled to move from the first end transverse bar to the second end transverse bar, and in response to at least one of the first detection member and the second detection member contacting the outermost edge of the second end transverse bar, the gate-shaped frame is controlled to move by a distance of L2 + Dh, and thereafter the detection assembly is controlled to move in the second direction, where Dh is the diameter of the transverse bar. Includes, The first end crossbar and the second end crossbar are the two crossbars at both ends of the reinforcing bar mesh, respectively.

[0013] In some embodiments, the first side length, the second side length, the third side width, and the fourth side width are the sum of all the coordinate differences H1 detected by the first detection member plus the diameter of the horizontal rib is taken as the first side length, the sum of all the coordinate differences H2 detected by the second detection member plus the diameter of the horizontal rib is taken as the second side length, when the portal frame is at the position of the third side, the sum of all the coordinate differences of the third detection member plus the diameter of the vertical rib is taken as the third side width, when the portal frame is at the position of the fourth side, the sum of all the coordinate differences of the third detection member plus the diameter of the vertical rib is taken as the fourth side width, determined by a method including

[0014] In some embodiments, a weld point detection model is stored in the weld point detection module, and detecting whether all the above-mentioned weld points are qualified is to compare the image of each weld point with the weld point detection model to determine whether each weld point is qualified, including

[0015] In some embodiments, recording the number of the above-mentioned unqualified weld points and counting the proportion they account for is to count the number of all unqualified weld points and the total number of all weld points on the steel bar mesh to calculate the overall unqualified rate of the weld points of the steel bar mesh, and to count the number of unqualified weld points on one steel bar and the total number of weld points on that steel bar to calculate the unqualified rate of the weld points of each steel bar, including

Brief Description of the Drawings

[0016] [Figure 1] It is a first view of a steel bar mesh quality inspection device and a steel bar mesh according to a specific embodiment of the present application. [Figure 2]This is a quality inspection device for a wire mesh according to a specific embodiment of the present application and a second view of the wire mesh. [Figure 3] This is a schematic diagram of a weld point detection module and a data processing module according to a specific embodiment of the present application.

Explanation of Reference Numerals

[0017] In the figure: 10... horizontal bars, 20... vertical bars, 110... first end horizontal bar, 120... second end horizontal bar, 210... first end vertical bar, 220... second end vertical bar, 1... portal frame, 11... first detection member, 12... second detection member, 2... detection assembly, 21... third detection member, 3... weld point detection module, 4... data processing module, 22... imaging unit, 23... image processing unit.

Mode for Carrying Out the Invention

[0018] Hereinafter, the present application will be described in combination with the drawings and examples. The examples described here are for interpreting the present application. For the sake of easy description, the drawings show parts related to the present application.

[0019] In the description of the present application, unless otherwise clearly defined and limited, the terms "connected", "connected to", and "fixed" should be understood in a broad sense. For example, it may be a fixed connection, a detachable connection, or integrated, a mechanical connection, an electrical connection, directly connected, indirectly connected through an intermediate medium, or the internal communication of two elements or the interaction relationship between two elements. A person skilled in the art can understand the specific meaning of the above terms in the present application according to the specific situation.

[0020] In this application, unless otherwise explicitly provided and limited, the presence of a first feature "above" or "below" a second feature may include direct contact between the first and second features, or it may include contact between them via another feature between them without direct contact. Furthermore, the presence of a first feature "above," "above," and "on the top surface" of a second feature may include the first feature being directly above and diagonally above the second feature, or indicating that the horizontal height of the first feature is greater than that of the second feature. The presence of a first feature "below," "below," and "on the bottom surface" of a second feature may include the first feature being directly below and diagonally below the second feature, or indicating that the horizontal height of the first feature is lower than that of the second feature.

[0021] In the description of this embodiment, terms such as "up," "down," "left," and "right" refer to directions or positional relationships based on the directions or positional relationships shown in the drawings. These terms are used to facilitate description and simplify operation, and do not indicate or suggest that the device or element in question necessarily has a specific direction or must be configured and operated in a specific direction. Furthermore, the terms "first" and "second" are used for distinction in the description and do not have any special meaning.

[0022] As shown in Figures 1 and 2, this embodiment provides a quality inspection device for a reinforcing steel mesh, wherein the reinforcing steel mesh includes a plurality of horizontal bars 10 arranged parallel to each other at intervals in a first direction, and a plurality of vertical bars 20 arranged parallel to each other at intervals in a second direction perpendicular to the first direction, and welding points are formed between the horizontal bars 10 and the vertical bars 20 by welding. The quality inspection device for the reinforcing steel mesh comprises a portal frame 1, a detection assembly 2, a welding point detection module 3, and a data processing module 4.

[0023] The gantry frame 1 extends in a second direction and is movable in the first direction. Each end of the gantry frame 1 is provided with a first detection member 11 and a second detection member 12 configured to detect the position of the transverse reinforcement bars 10. The detection assembly 2 is mounted on the gantry frame 1 so as to be movable in the second direction. The detection assembly 2 is provided with a third detection member 21 configured to detect the position of the longitudinal reinforcement bars 20. The welding point detection module 3 collects images of welding points and can determine whether the welding points are pass or fail based on the images. The data processing module 4 communicates with the first detection member 11, the second detection member 12, the third detection member 21, and the welding point detection module 3. The data processing module 4 is configured to obtain the spacing between adjacent horizontal reinforcements 10, the spacing between adjacent vertical reinforcements 20, the pass / fail status of the protrusion length of the horizontal reinforcements 10 into the reinforcing mesh, the pass / fail status of the protrusion length of the vertical reinforcements 20 into the reinforcing mesh, and the diagonal of the reinforcing mesh from the detected values ​​of the first detection member 11, the second detection member 12, and the third detection member 21. Furthermore, the data processing module 4 is configured to statistically calculate the failure rate of the weld points.

[0024] When the portal frame 1 is controlled to move in a first direction, the first detection member 11 and the second detection member 12 scan the transverse bars 10 of the reinforcing mesh to acquire their positions. When the detection assembly 2 is moved in a second direction, the third detection member 21 scans the longitudinal bars 20 of the reinforcing mesh to acquire their positions. Based on the positions of the transverse bars 10 and longitudinal bars 20 acquired by the first detection member 11, the second detection member 12, and the third detection member 21, it is possible to determine the spacing between the transverse bars 10, the spacing between the longitudinal bars 20, the pass / fail status of the protrusion lengths of the transverse bars 10 and longitudinal bars 20 from the reinforcing mesh, and the pass / fail status of the diagonal dimensions of the reinforcing mesh. This allows for the detection of the external shape and dimensions of the reinforcing mesh in all directions. The welding point detection module 3 can determine the pass / fail status of the welding points between the transverse bars 10 and longitudinal bars 20, and further determine whether the welding quality of the reinforcing mesh meets the standard. The reinforcing mesh quality inspection device and quality inspection method enable automatic detection of the quality of reinforcing mesh, improve the efficiency of reinforcing mesh quality inspection, guarantee the acceptance quality of reinforcing mesh, and realize digitized and intelligent quality inspection of reinforcing mesh.

[0025] In some embodiments, at least one of the first detection member 11, the second detection member 12, and the third detection member 21 is equipped with a position sensor.

[0026] Preferably, the first detection member 11 is equipped with a first position sensor, the second detection member 12 is equipped with a second position sensor, and the third detection member 21 is equipped with a third position sensor. The position sensors are highly accurate and can correctly acquire the positions of the horizontal reinforcement bars 10 and vertical reinforcement bars 20, thereby improving the reliability of quality inspection of the reinforcing steel mesh.

[0027] In some embodiments, the welding point detection module 3 includes an imaging unit 22 configured to capture images including welding points in real time, and an image processing unit 23 configured to receive images including welding points captured by the imaging unit 22 and to determine whether the welding points are pass or fail according to the images. Exemplarily, as shown in Figure 3, in this embodiment, the imaging unit 22 may be provided in the detection assembly 2, the imaging unit 22 employs an industrial camera, the imaging unit 22 is communicated to the image processing unit 23 via a network cable, and the image processing unit 23 implements an object detection algorithm.

[0028] In some embodiments, the image processing unit 23 and the data processing module 4 may be located on the same or different computers, which may be remote computers or computers located at the quality inspection site. For example, as shown in Figure 3, in this embodiment, the image processing unit 23 and the data processing module 4 are located on the same computer (Personal Computer, PC) in a remote control room.

[0029] Based on the above-described quality inspection device for reinforcing mesh, this embodiment further provides a quality inspection method for reinforcing mesh, which includes the following steps.

[0030] In S1, the portal frame 1 is controlled to move in a first direction, and during that time, the first detection member 11 and the second detection member 12 detect the position coordinates of the transverse bars 10, and the spacing between adjacent transverse bars 10 is obtained from at least one of the detected values ​​of the first detection member 11 and the second detection member 12. That is, the spacing between the transverse bars 10 may be obtained based on the detected value of the first detection member 11, or based on the detected value of the second detection member 12, or the spacing between the transverse bars 10 may be obtained by combining the detected values ​​of the first detection member 11 and the second detection member 12, and the obtained spacing values ​​of the transverse bars 10 are compared with a specified range to confirm whether the spacing of the transverse bars 10 in the reinforcing bar mesh is acceptable.

[0031] In this embodiment, in step S1, when the first detection member 11 and the second detection member 12 move to the outermost edge of the horizontal bar 10, a signal is triggered. The coordinate differences when the first detection member 11 and the second detection member 12 trigger the signal twice, before and after, are defined as H1 and H2, respectively, and it is determined whether the average value of H1 and H2 is within a specified range of the spacing of the horizontal bar 10.

[0032] In some embodiments, a signal is considered triggered when the first detection member 11 or the second detection member 12 moves to the upper edge of one transverse bar 10, and a signal is considered triggered twice, once before and once after, when the first detection member 11 or the second detection member 12 moves from the upper edge of the first transverse bar to the upper edge of the second transverse bar (the first and second transverse bars are adjacent to each other). In other embodiments, the signal may be triggered with the lower edge of the transverse bar 10 as the outermost edge.

[0033] For example, when the gantry frame 1 moves in a first direction, the first detection member 11 records the vertical position coordinate Yn when it triggered the previous signal and the vertical position coordinate Y(n+1) when it triggered the next signal. The difference obtained by subtracting Yn from Y(n+1) is H1, and the spacing of the horizontal bars 10 on the side where the first detection member 11 is located is obtained. At the same time, the second detection member 12 records the vertical position coordinate Ym when it triggered the previous signal and the vertical position coordinate Y(m+1) when it triggered the next signal. The difference obtained by subtracting Ym from Y(m+1) is H2, and the spacing of the horizontal bars 10 on the side where the second detection member 12 is located is obtained. By using the average of H1 and H2 as the spacing of the horizontal bars 10, the data becomes more reliable.

[0034] The spacing of the horizontal reinforcement bars can be an integer multiple of 25 millimeters (mm), with a minimum spacing of 100 mm. The allowable deviation of the spacing shall be the larger of ±10 mm from the specified spacing or ±5% from the specified spacing.

[0035] In S2, the detection assembly 2 is controlled to move in a second direction, during which time the third detection member 21 detects the position coordinates of the vertical reinforcement bars 20, and the spacing between adjacent vertical reinforcement bars 20 is obtained from the values ​​detected by the third detection member 21.

[0036] In this embodiment, in step S2, a signal is triggered when the third detection member 21 moves to the outermost edge of the vertical reinforcement bar 20, and the difference in coordinates when the third detection member 21 triggers the signal twice, before and after, is taken as the interval of the vertical reinforcement bar 20. That is, the third detection member 21 triggers a signal immediately after scanning the vertical reinforcement bar 20 and records the position coordinates.

[0037] In some embodiments, a signal is considered triggered when the third detection member 21 moves to the left edge of one vertical bar 20, and a signal is considered triggered twice, one before and one after, when the second detection member 12 moves from the left edge of the first vertical bar to the left edge of the second vertical bar (the first and second vertical bars are adjacent to each other). In other embodiments, the signal may be triggered with the right edge of the vertical bar 20 as the outermost edge.

[0038] For example, when the detection assembly 2 moves in a second direction, the third detection member 21 records the lateral position coordinate Xn when it previously triggered a signal and the lateral position coordinate X(n+1) when it next triggers a signal, and the difference obtained by subtracting Xn from X(n+1) becomes the spacing value of the vertical reinforcement bars 20.

[0039] The spacing of the vertical reinforcement bars 20 can be an integer multiple of 50 mm, with a minimum spacing of 100 mm. The allowable deviation of the spacing shall be the larger of ±10 mm of the specified spacing or ±5% of the specified spacing.

[0040] In one embodiment, when detecting the spacing of the vertical reinforcement bars 20, the portal frame 1 is sequentially moved in a first direction from one end to the other of the reinforcing bar network to multiple inspection points. The portal frame 1 is then stopped once at each inspection point, and the detection assembly 2 is controlled to detect the spacing of the vertical reinforcement bars 20 at that inspection point. In this way, there are multiple sets of data for the spacing between each pair of adjacent vertical reinforcement bars 20, and the average value can be calculated and then compared with the specified spacing of the vertical reinforcement bars 20.

[0041] In this embodiment, referring to Figure 2, the portal frame 1 is provided with multiple detection assemblies 2. Each detection assembly 2 is responsible for a portion of the area and detects the position of the vertical reinforcement bars 20 within its assigned area, thereby obtaining the spacing of the vertical reinforcement bars 20 within that area. By using multiple detection assemblies 2, the spacing values ​​of all the vertical reinforcement bars 20 in the reinforcing bar network can be obtained quickly, improving detection efficiency. Of course, in other embodiments, only one detection assembly 2 may be provided.

[0042] In S3, the assembly 2 is moved in parallel to control the third detection member 21 to move by a first predetermined distance L1 away from the outermost part of the vertical reinforcement 20 located at the end, and then the portal frame 1 is moved in parallel to control the third detection member 21 to detect the horizontal reinforcement 10, and the protruding length of the horizontal reinforcement 10 relative to the reinforcing mesh is set to pass.

[0043] Referring to Figures 1 and 2, in step S3, the detection assembly 2 is moved from the first end longitudinal reinforcement 210 towards the second end longitudinal reinforcement 220. When the third detection member 21 contacts the outermost edge of the second end longitudinal reinforcement 220, the detection assembly 2 is controlled to move by a distance of L1 + Dz, and then the portal frame 1 is controlled to move in parallel. Dz is the diameter of the longitudinal reinforcement 20, and the first end longitudinal reinforcement 210 and the second end longitudinal reinforcement 220 are the two longitudinal reinforcements 20 at both ends of the reinforcement mesh, respectively.

[0044] The first predetermined distance L1 is exemplified as 25 mm. The detection assembly 2 on the far right in Figure 2 is controlled to operate, and when the third detection member 21 in it contacts the outermost edge of the first end vertical reinforcement 210, the operation is stopped, and this becomes the starting position for detecting the protrusion length of the first end of the horizontal reinforcement 10. Subsequently, the detection assembly 2 is controlled to move 25 mm (to the right in Figure 2) away from the reinforcing mesh. Next, the portal frame 1 is controlled to move parallel to the first direction. During this period, if the third detection member 21 detects the horizontal reinforcement 10, it indicates that the protrusion length of the first end of the horizontal reinforcement 10 relative to the reinforcing mesh is 25 mm or more, and the system passes. Conversely, if the third detection member 21 does not detect the horizontal reinforcement 10, it indicates that the protrusion length of the first end of the horizontal reinforcement 10 relative to the reinforcing mesh is less than 25 mm, and the system fails.

[0045] Similarly, the leftmost detection assembly 2 in Figure 2 is controlled to operate, and when the third detection member 21 in it contacts the outermost edge of the second end vertical reinforcement 220, the operation is stopped, setting this as the starting position for detecting the protrusion length of the second end of the transverse reinforcement 10. Subsequently, the detection assembly 2 is controlled to move 25 mm + Dz distance (to the left in Figure 2) away from the reinforcing mesh. Next, the portal frame 1 is controlled to move parallel to the first direction, and if the third detection member 21 detects the transverse reinforcement 10 during this period, it indicates that the protrusion length of the second end of the transverse reinforcement 10 relative to the reinforcing mesh is 25 mm or more, and the test is deemed successful. Conversely, if the third detection member 21 does not detect the transverse reinforcement 10, it indicates that the protrusion length of the second end of the transverse reinforcement 10 relative to the reinforcing mesh is less than 25 mm, and the test is deemed unsuccessful.

[0046] In S4, the portal frame 1 is moved in parallel to control the first detection member 11 or the second detection member 12 to move by a second predetermined distance L2 in the direction away from the outermost side of the horizontal bar 10 located at the end, and then the detection assembly 2 is moved in parallel to control the detection assembly 2, and if the third detection member 21 detects the vertical bar 20, the protruding length of the vertical bar 20 relative to the reinforcing mesh is deemed acceptable.

[0047] In step S4, the portal frame 1 is moved from the first end transverse bar 110 towards the second end transverse bar 120. When at least one of the first detection member 11 and the second detection member 12 contacts the outermost edge of the second end transverse bar 120, the portal frame 1 is controlled to move by a distance of L2 + Dh, and then the detection assembly 2 is controlled to move in parallel. Dh is the diameter of the transverse bar 10, and the first end transverse bar 110 and the second end transverse bar 120 are the two transverse bars 10 at both ends of the reinforcing bar mesh, respectively.

[0048] Referring to Figures 1 and 2, the second predetermined distance L2 is exemplified as 25 mm. The gate-type frame 1 is controlled to move in parallel, and when the first detection member 11 or the second detection member 12 contacts the outermost edge of the first end transverse reinforcement 110, the operation is stopped, and this becomes the starting position for detecting the protrusion length of the first end of the longitudinal reinforcement 20. Subsequently, the gate-type frame 1 is controlled to move 25 mm (upward in Figure 2) in the direction away from the reinforcing mesh. Next, the detection assembly 2 is controlled to move in parallel, and during this period, if the third detection member 21 detects the longitudinal reinforcement 20, it indicates that the protrusion length of the first end of the longitudinal reinforcement 20 relative to the reinforcing mesh is 25 mm or more, and the system passes. Conversely, if the third detection member 21 does not detect the transverse reinforcement 10, it indicates that the protrusion length of the first end of the longitudinal reinforcement 20 relative to the reinforcing mesh is less than 25 mm, and the system fails.

[0049] Similarly, when the first detection member 11 or the second detection member 12 comes into contact with the outermost edge of the second end transverse reinforcement 120, the operation is stopped, and the detection of the protruding length of the first end of the longitudinal reinforcement 20 is started. Subsequently, the gate-type frame 1 is controlled to move 25 mm + Dh distance (downward in Figure 2) away from the reinforcing mesh. Next, the detection assembly 2 is controlled to move in parallel, and if the third detection member 21 detects the longitudinal reinforcement 20 during this period, it indicates that the protruding length of the second end of the longitudinal reinforcement 20 relative to the reinforcing mesh is 25 mm or more, and the system passes. Conversely, if the third detection member 21 does not detect the transverse reinforcement 10, it indicates that the protruding length of the second end of the longitudinal reinforcement 20 relative to the reinforcing mesh is less than 25 mm, and the system fails.

[0050] In S5, the first and second side lengths of the reinforcing bar mesh are determined based on the spacing between adjacent horizontal bars 10 and the diameter Dh of the horizontal bars 10, and the third and fourth side widths of the reinforcing bar mesh are determined based on the spacing between adjacent vertical bars 20 and the diameter Dz of the vertical bars 20.

[0051] For example, in step S5, the sum of all coordinate differences H1 detected by the first detection member 11 plus the diameter Dh of the horizontal reinforcement 10 is used to determine the first side length. That is, the sum of the spacing between the horizontal reinforcement 10 detected by the first detection member 11 plus the diameter Dh of the horizontal reinforcement 10 is used to determine the right side length Lg1 of the reinforcing bar mesh in Figure 2.

[0052] The second side length is obtained by adding the diameter Dh of the horizontal reinforcement bar 10 to the sum of all coordinate differences H2 detected by the second detection member 12. That is, the left side length Lg2 of the reinforcing bar mesh in Figure 2 is obtained by adding the diameter Dh of the horizontal reinforcement bar 10 to the sum of the spacing of the horizontal reinforcement bars 10 detected by the second detection member 12.

[0053] When the portal frame 1 is at the position of the third side, the width of the third side is obtained by adding the diameter Dz of the vertical reinforcement bar 20 to the sum of the coordinate differences of all the third detection members 21. That is, when the portal frame 1 is at the position of the first end horizontal reinforcement bar 110, the upper width Lg3 of the reinforcement mesh in Figure 2 is obtained by adding the diameter Dz of the vertical reinforcement bar 20 to the sum of the spacing of all the vertical reinforcement bars 20 detected by the multiple third detection members 21.

[0054] When the portal frame 1 is at the position of the fourth side, the fourth side width is obtained by adding the diameter Dz of the vertical reinforcement bar 20 to the sum of the coordinate differences of all the third detection members 21. That is, when the portal frame 1 is at the position of the second end horizontal reinforcement bar 120, the lower side width Lg4 of the reinforcement mesh in Figure 2 is obtained by adding the diameter Dz of the vertical reinforcement bar 20 to the sum of the spacing of all the vertical reinforcement bars 20 detected by the multiple third detection members 21.

[0055] The allowable deviations for the length and width of the reinforcing mesh shall be the larger of ±25 mm from the specified length and width values ​​or ±0.5% from the specified length and width values.

[0056] In S6, the lengths of the two diagonals of the reinforcing mesh are determined based on the quadrilateral enclosed by the first, second, third, and fourth sides of the reinforcing mesh, and it is determined whether the ratio of the two diagonals is within the error range.

[0057] Based on the lengths of the four sides of the reinforcing mesh obtained in step S5, the lengths of the two diagonals of the reinforcing mesh are calculated, and the ratio of the lengths of the two diagonals is the diagonal difference. The allowable deviation of the diagonal difference is ±0.5% of the specified diagonal difference.

[0058] In one embodiment, referring to Figure 1, the figure shows two diagonal lines D1 and D2 of the reinforcing mesh.

[0059] In S7, the welding point detection module 3 is controlled to collect images of all welding points and to detect whether the quality of all welding points is acceptable or not.

[0060] In step S7, the welding point detection module 3 stores a welding point detection model, and by comparing the image of the welding point with the welding point detection model, it determines whether the quality of the welding point is acceptable or not.

[0061] For example, the welding point detection model employs an object detection algorithm, specifically yolov8, and the pre-training weight parameters are yolov8m. The object detection algorithm according to this application can also employ other object detection algorithms such as the YOLO series, Fast RCNN series, SSD series, etc. When creating a welding point detection model, it is necessary to first collect a certain number of welding point images, and then label the features of each welding point image. For labeling, binary classification labels such as "pass" and "fail" may be directly used, or multiple feature labels may be defined for the features of the welding point, such as "sufficient build-up," "indentation," "bias," and "weld detachment," and then the quality inspection result of the welding point is obtained through multi-feature fusion inference.

[0062] After labeling the weld point images and training the object detection algorithm, a weld point detection model is obtained. This model is then deployed to the control computer of the on-site rebar quality inspection device. Upon receiving a signal that welding is complete, the control computer controls the image acquisition module (e.g., camera) of the rebar quality inspection device to collect images of the weld points, use these images to perform a quality inspection of the weld points, and obtain the weld point detection results.

[0063] In S8, the number of unsatisfactory welds is recorded, and their proportion is statistically calculated.

[0064] In step S8, the total number of failed welds and the total number of welds on the reinforcing mesh are statistically calculated to determine the overall weld failure rate of the reinforcing mesh. The ratio between the total number of failed welds and the total number of welds on the reinforcing mesh is defined as the overall weld failure rate, and the overall weld failure rate must be less than 1%.

[0065] Furthermore, the number of unacceptable welds on a single reinforcing bar and the total number of welds on that reinforcing bar are statistically analyzed to calculate the failure rate of the welds on each reinforcing bar. The ratio between the number of unacceptable welds on a single reinforcing bar and the total number of welds on that reinforcing bar is defined as the failure rate of the welds on a single reinforcing bar. For reinforcing bars in the intermediate positions, the failure rate of the welds on a single reinforcing bar must be less than 50%, and for the outermost reinforcing bars, i.e., the first end transverse reinforcement 110, the second end transverse reinforcement 120, the first end longitudinal reinforcement 210, and the second end longitudinal reinforcement 220, the pass rate of the welds must be 100%.

[0066] In this embodiment, the reinforcing mesh quality inspection device is a welding robot. First position sensors and second position sensors are positioned at both ends of the gantry frame 1 of the welding robot. Multiple welding guns are mounted on the gantry frame 1 of the welding robot so as to be movable in a second direction, and one detection assembly 2 is provided on each welding gun. After the welding robot completes welding the reinforcing mesh, it can also perform quality inspection of the reinforcing mesh, reducing the operating process and improving quality inspection efficiency.

[0067] In some embodiments, the welding robot controller can communicate with a computer (PC) in Figure 3 via a network cable and is used to control the data processing module 4 and the image processing unit 23 in the welding point detection module 3 to perform data analysis and processing. Exemplarily, each welding gun is equipped with a camera to perform detection immediately after welding, the welding point detection module 3 collects real-time welding point images and then identifies the quality of the welding point in real time using an object detection algorithm (e.g., YOLOV8), the data processing module 4 collects data from the welding robot controller in real time, calculates relevant data for the first detection member 11, the second detection member 12 and the third detection member 21, and can statistically calculate the pass rate of the welding point detection results of the welding point detection module 3.

Claims

1. A quality inspection device for a reinforcing steel mesh, wherein the plurality of reinforcing bars in the reinforcing steel mesh include a plurality of horizontal bars (10) spaced parallel to each other in a first direction and a plurality of vertical bars (20) spaced parallel to each other in a second direction perpendicular to the first direction, and welding points are formed between the horizontal bars (10) and the vertical bars (20) by welding. The aforementioned reinforcing mesh quality inspection device is, A portal frame (1) extends in the second direction and is movable in parallel in the first direction, and each of its ends is provided with a first detection member (11) and a second detection member (12) configured to detect the position of the transverse reinforcement bars (10), A detection assembly (2) is provided on the gate-type frame (1) so as to be movable in a second direction, and a third detection member (21) is provided which is configured to detect the position of the vertical reinforcement bars (20), A welding point detection module (3) that collects images of the welding points and can determine whether the welding points are pass or fail according to the images, A data processing module (4) is configured to obtain, from the detected values ​​of the first detection member (11), the second detection member (12), and the third detection member (21), the spacing between adjacent horizontal reinforcements (10), the spacing between adjacent vertical reinforcements (20), the pass / fail status of the protrusion length of the horizontal reinforcements (10) relative to the reinforcing mesh, the pass / fail status of the protrusion length of the vertical reinforcements (20) relative to the reinforcing mesh, and the diagonal of the reinforcing mesh, and is further configured to statistically calculate the failure rate of the welding points, Equipped with, A quality inspection device for reinforcing steel mesh.

2. At least one of the first detection member (11), the second detection member (12), and the third detection member (21) is equipped with a position sensor. The reinforcing steel mesh quality inspection apparatus according to claim 1.

3. A method for inspecting the quality of a reinforcing mesh using the reinforcing mesh quality inspection device described in claim 1 or 2, The gate-type frame (1) is controlled to move in the first direction, and during that period, the first detection member (11) and the second detection member (12) detect the position coordinates of the horizontal bars (10), and the interval between adjacent horizontal bars (10) is obtained from at least one of the detected values ​​of the first detection member (11) and the second detection member (12). The detection assembly (2) is controlled to move in the second direction, during which time the third detection member (21) detects the position coordinates of the vertical reinforcement bars (20), and the interval between adjacent vertical reinforcement bars (20) is obtained from the detected values ​​of the third detection member (21). The detection assembly (2) is moved in parallel to control the third detection member (21) to move by a first predetermined distance L1 away from the outermost part of the vertical reinforcement (20) located at the end, and then the portal frame (1) is moved in parallel in the first direction, and in response to the third detection member (21) detecting the horizontal reinforcement (10), the protruding length of the horizontal reinforcement (10) relative to the reinforcing mesh is set to pass. The gate-type frame (1) is moved in parallel to control the first detection member (11) or the second detection member (12) to move by a second predetermined distance L2 in the direction away from the outermost part of the horizontal reinforcement (10) located at the end, and then the detection assembly (2) is moved in parallel in the second direction, and in response to the third detection member (21) detecting the vertical reinforcement (20), the protruding length of the vertical reinforcement (20) relative to the reinforcing mesh is set to pass. The first side length Lg1 and the second side length Lg2 of the reinforcing mesh are determined based on the spacing between adjacent horizontal bars (10) and the diameter Dh of the horizontal bars (10), and the third side width Lg3 and the fourth side width Lg4 of the reinforcing mesh are determined based on the spacing between adjacent vertical bars (20) and the diameter Dz of the vertical bars (20), Based on the rectangle enclosed by the first, second, third, and fourth sides of the reinforcing mesh, the lengths of the two diagonals of the reinforcing mesh are determined, and it is determined whether the ratio of the two diagonals is within the error range. The welding point detection module (3) is controlled to collect images of all the welding points and to detect whether the quality of all the welding points is acceptable or not. Record the number of unsatisfactory welds and statistically determine their proportion. including, Quality inspection method for reinforcing steel mesh.

4. The aforementioned method, When the first detection member (11) and the second detection member (12) move to the outermost edge of the horizontal bar (10), a signal is triggered, and the coordinate differences when the first detection member (11) and the second detection member (12) trigger the signal twice, before and after, are defined as H1 and H2, respectively, and it is determined whether the average value of H1 and H2 is within a specified range for the spacing of the horizontal bar (10). Further including, The method for inspecting the quality of a reinforcing steel mesh according to claim 3.

5. The spacing between the vertical lines (20) is When the third detection member (21) moves to the outermost edge of the vertical stripe (20), a signal is triggered, and the difference in coordinates when the third detection member (21) triggers the signal twice, before and after, is defined as the spacing of the vertical stripe (20). It is determined by the following method: The method for inspecting the quality of a reinforcing steel mesh according to claim 4.

6. Controlling the detection assembly (2) to move the third detection member (21) by a first predetermined distance L1 away from the outermost part of the vertical reinforcement (20) located at the end, and then controlling the portal frame (1) to move in the first direction, The detection assembly (2) is controlled to move from the first end longitudinal reinforcement (210) towards the second end longitudinal reinforcement (220), and in response to the third detection member (21) contacting the outermost edge of the second end longitudinal reinforcement (220), the detection assembly (2) is controlled to move by a distance of L1 + Dz, where Dz is the diameter of the longitudinal reinforcement (20), and thereafter the gate-type frame (1) is controlled to move in the first direction. Includes, The first end vertical reinforcement (210) and the second end vertical reinforcement (220) are the two vertical reinforcements (20) at both ends of the reinforcing bar mesh, respectively. The method for inspecting the quality of a reinforcing steel mesh according to claim 5.

7. Controlling the portal frame (1) to move the first detection member (11) or the second detection member (12) by a second predetermined distance L2 in the direction away from the outermost part of the transverse bar (10) located at the end, and then controlling the detection assembly (2) to move in the second direction, The gate-shaped frame (1) is controlled to move from the first end transverse bar (110) towards the second end transverse bar (120), and in response to at least one of the first detection member (11) and the second detection member (12) contacting the outermost edge of the second end transverse bar (120), the gate-shaped frame (1) is controlled to move by a distance of L2 + Dh, where Dh is the diameter of the transverse bar (10), and thereafter the detection assembly (2) is controlled to move in parallel in the second direction. Includes, The first end crossbar (110) and the second end crossbar (120) are the two crossbars (10) at both ends of the reinforcing bar mesh, respectively. The method for inspecting the quality of a reinforcing steel mesh according to claim 5.

8. The first side length Lg1 and the second side length Lg2, and the third side width Lg3 and the fourth side width Lg4 are, The sum of all coordinate differences H1 detected by the first detection member (11) is added to the diameter Dh of the horizontal reinforcement (10) to obtain the first side length Lg1, The second side length Lg2 is obtained by adding the diameter Dh of the transverse reinforcement (10) to the sum of all coordinate differences H2 detected by the second detection member (12), When the gate-type frame (1) is at the position of the third side, the sum of all coordinate differences of the third detection member (21) plus the diameter Dz of the vertical reinforcement (20) is used to determine the width Lg3 of the third side, When the gate-type frame (1) is at the position of the fourth side, the sum of all coordinate differences of the third detection member (21) plus the diameter Dz of the vertical reinforcement (20) is used to determine the width Lg4 of the fourth side, Determined by a method including, The method for inspecting the quality of a reinforcing steel mesh according to claim 5.

9. The welding point detection module (3) stores a welding point detection model, and the ability to detect whether the quality of all the welding points is acceptable or unacceptable is as follows: The quality of each welding point is determined by comparing the image of each welding point with the welding point detection model. including, The method for inspecting the quality of a reinforcing steel mesh according to claim 3.

10. Recording the number of unsatisfactory welds and statistically determining their proportion is: The number of all unsuccessful welds and the total number of welds on the reinforcing mesh are statistically calculated to determine the overall failure rate of welds on the reinforcing mesh. The number of unacceptable welds on a single reinforcing bar and the total number of welds on that reinforcing bar are statistically analyzed to calculate the unacceptable rate of welds on each reinforcing bar. including, The method for inspecting the quality of a reinforcing steel mesh according to claim 3.

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