Apparatus for feeding reinforcement elements into an assembly station, an assembly station, a system and a method of assembling a reinforcement cage

Abstract

The present invention relates to an apparatus for feeding reinforcement elements into an assembly station, an assembly station for assembling a reinforcement cage, and system and method thereof. The apparatus comprises at least one robotic unit with at least one robot arm, where at least one tool is attachable to the free end of the robot arm. The robotic unit is configured to pick up longitudinal reinforcement elements from a loading end or table, and to position them relative to a reinforcement cage in the assembly station. The longitudinal reinforcement elements are pushed in the assembly station by the robotic unit. The longitudinal reinforcement elements may be pre-assembled into sets and then orientated relative to the reinforcement cage, before being attached to the transverse stirrups.

Description

[0001] Apparatus for feeding reinforcement elements into an assembly station, an assembly station, a system and a method of assembling a reinforcement cage

[0002] Field of the Invention

[0003] The present invention relates to an apparatus configured to feed reinforcement elements into an assembly station, wherein the apparatus comprises a feeding unit configured to pick up and orientate the reinforcement elements relative to the assembly station. The reinforcement elements are then fed into the assembly station by the feeding unit. The assembly station comprises a conveyor unit connected to a lifting mechanism for moving the conveyor unit into a selected installation height, wherein the conveyor unit comprises a guide element for moving the longitudinal reinforcement element into assembly points relative to transverse reinforcement elements.

[0004] The present invention further relates to a system and a method of assembling a reinforcement cage.

[0005] Background of the Invention

[0006] It is known that reinforcement cages can be assembled and embedded into concrete structures for added structural strength. This can be performed onsite or offsite by tying or welding the reinforcement elements together one by one using a time-consuming manual assembly process. The assembled reinforcement cage may then be transported to the installation site and lifted into position.

[0007] One way to reduce the assembly time and increase safety for the workers is to preassembly the reinforcement cages using assembly stations. The assembly station comprises supports for supporting the reinforcement elements during assembly, where the respective reinforcement elements are tied or welded together at points along the cage structure using industrial robots.

[0008] It is known to use an overhead gantry system to move one or more robot arms relative to the assembly area, where the robot arms are fitted with a tying or welding tool to attach the longitudinal and transverse reinforcement elements together. The longitudinal reinforcement elements and / or the transverse reinforcement elements may be manually fed into the assembly area or automatically by the robot arms. However, these above assembly stations and gantry systems are only capable of handling reinforcement elements with a maximum diameter of less than 16 millimetres. WO 2020 / 187379 A1 discloses an assembly station comprising robotic units arranged on rails, where each robotic unit comprises a robot arm with a tool. A plurality of supports is distributed along the production area for supporting the transverse reinforcement elements. Further, a plurality of support arms is arranged along the production area for supporting the longitudinal reinforcement elements, which are connected to a lifting mechanism for moving the support arms in the height direction.

[0009] A first feeding unit is arranged at a first feeding end for feeding the longitudinal reinforcement elements into the assembly station. The first feeding unit comprises local drive mechanisms for feeding the reinforcement elements into the assembly station. A second feeding unit is arranged at a second feeding end for feeding the transverse stirrups into the assembly station. The second feeding unit comprises a pre-assembly station for assembling the stirrups before they are fed into the assembly station.

[0010] WO 2020 / 187378 A1 discloses a similar assembly station where the stirrups are loaded onto a holding element positioned at the second feeding end. The longitudinal reinforcement elements are fed into the assembly area and positioned on the support arms. The holding element is moved along the rails together with the robotic units, where a first robot at each installation position picks up a stirrup and positioned it relative to the longitudinal reinforcement elements. A second robot welds the stirrup to one or more longitudinal reinforcement elements.

[0011] Although the above assembly stations are capable of handling reinforcement elements with a diameter greater than 16 millimetres, some limitations still exit.

[0012] There is a need for an improved assembly station and feeding unit that are capable of handling sets of reinforcement elements and producing complex reinforcement cages.

[0013] Object of the Invention

[0014] One objective of the present disclosure is to achieve a system and method that overcomes the abovementioned problems of the prior art.

[0015] One objective of the present disclosure is to achieve a system and method capable of handling sets of longitudinal reinforcement elements.

[0016] One objective of the present disclosure is to achieve a system and method of producing complex reinforcement cages. Description of the Invention

[0017] One objective of the invention is achieved by an apparatus, according to claim 1 , for feeding reinforcement elements into an assembly station, the apparatus defines an infeed end and a loading end, the comprising:

[0018] - at least one feeding unit with at least one tool configured to pick up the reinforcement elements,

[0019] - the least one feeding unit is configured to move the reinforcement elements into an infeed position at the infeed end, the infeed position corresponding to a position of a conveyor unit in the assembly station,

[0020] - wherein the feeding unit comprises at least one robotic unit with at least one robot arm, where the tool is configured to be attached to a free end of the robot arm, the feeding unit being configured to feed the reinforcement elements into the assembly station.

[0021] This provides an apparatus capable of handling automatically using robotic units. The present apparatus provides increased functionality when feeding the reinforcement elements into the assembly station at different infeed positions at different infeed heights. The present apparatus is configured to interact with the assembly station during the feeding process to align the longitudinal reinforcement elements with the conveyor unit(s) in the assembly station.

[0022] The apparatus extends in a longitudinal direction, a transverse direction and a height direction. The apparatus has a loading end for loading, manually or automatically, the longitudinal reinforcement elements into the apparatus. Furthermore, the apparatus has an infeed end for feeding the reinforcement elements into the assembly station. One or more feeding units are arranged between the infeed end and the loading end and are configured to pick up the reinforcement elements and push them into the assembly station.

[0023] In the present invention, the feeding units are robotic units with one or more robot arms each having a free end. The robot arms are configured to have multiple degrees of freedoms (DOF) so that they can be moved along multiple axis. Preferably, the robot arms may be moved along the X-, Y- and Z-axes. A tool is adapted to be attached to the free end of the robot arm permanently or via matching coupling elements. The tool is configured to pick up and hold one or more reinforcement elements. This allows the robotic units to move into a loading position at the loading end and further into an infeed position at the infeed end. In one embodiment, the at least one robotic unit is configured to move along at least one rail extending in at least a longitudinal or transverse direction of the apparatus.

[0024] One or more of the robotic units may be moveably arranged on individual rails. Alternatively, two or more robotic units may be moveably arranged on a shared rail. The rails may extend in the longitudinal direction and / or the transverse direction. This allows all or some of the robotic units to move between the loading and feeding ends.

[0025] The movements of the respective robotic units and their respective robot arms may be controlled by a control unit, preferably a local or central control unit. Furthermore, the operation of the tools may also be controlled by the control unit.

[0026] In one embodiment, the apparatus comprises a first robotic unit and at least a second robotic unit, the first robotic unit comprising first robot arm with a first tool, and the second robotic unit comprising second robot arm with a second tool.

[0027] The apparatus may comprise at least two robotic units, each with at least one robot arm with a free end. A first robotic unit may be arranged relative to the infeed end while at least a second robotic unit may be arranged relative to the loading end. The first robotic unit may be arranged on a first rail. The second robotic unit(s) may be arranged on a second rail. The first and second rails may be angled relative to each other so that they may move in different directions. The angle may be selected between 0-180 degrees. T This allows the robotic units to move relative to each other to bring the longitudinal reinforcement elements in their respective infeed positions relative to the assembly station.

[0028] The first robotic unit may be used to bring the longitudinal reinforcement elements into an infeed position aligned with the guide elements on the conveyor units in the assembly station in the transverse and height directions. The second robotic unit(s) may be used to place the longitudinal reinforcement elements in the correct infeed angle relative to the guide elements. This may be achieved by adjusting a second infeed position at the second robotic unit(s) relative to a first infeed position at the first robotic unit in the transverse direction and / or the height direction. For example, a centreline of the reinforcement elements extending through the first and second infeed positions may be aligned with a longitudinal axis. For example, the centreline may be angled relative the longitudinal axis in the transverse direction and / or the height direction. The angle may be selected between ±45 degrees relative to the longitudinal axis. This increases the functionality of the apparatus compared with other apparatuses as they are only capable of feeding the longitudinal reinforcement elements into the assembly station along the longitudinal axis.

[0029] In one embodiment, the first and second robotic units are connected to a control unit, which is configured to operate the first and second robotic units in synchronisation or independently, preferably the first and second robotic units being configured to rotate the reinforcement elements into an infeed angle relative to the reinforcement cage in the assembly station under control of the control unit.

[0030] The apparatus may comprise a local control unit capable of communicating with other control units, such as the control unit of the assembly station. The control unit may control the operation of the tools and / or the relative movement of the respective robotic units using sensors, cameras or a combination thereof. The control unit may receive data about the dimensions of the reinforcement elements or sets thereof. The control unit may also receive position data for the respective reinforcement elements or sets thereof. The control unit may use the received data to control the infeed process of the reinforcement elements.

[0031] In one embodiment, the at least one tool comprises adjustable gripping elements configured to be adjusted relative to the width of a selected reinforcement element or a set of reinforcement elements.

[0032] The present invention may comprise one or more tools, each with moveable gripping elements configured to grip a reinforcement element or a set thereof. Preferably, the gripping elements may be adjustable in a width direction so that they are able to reinforcements, or sets thereof, of different dimensions. Various gripping tools for robotic units are known, but specially designed gripping tools may also be used. This allows the robotic units to pick up individual reinforcement elements as well as sets of reinforcement elements.

[0033] The tools of the present invention may receive hydraulic, pneumatic and / or electrical power via one or more supply lines. The supply lines may be connected to the tool via matching coupling elements. The robotic units and tools may be powered by a local power source within the apparatus or an external power source. In one embodiment, the at least one tool comprises a drive mechanism configured to actively move the reinforcement element or the set of reinforcement elements in the longitudinal direction and / or transverse direction.

[0034] One or more tools of the present invention may further comprise a local drive mechanism configured to actively move the reinforcement elements in one or more directions. The gripping elements may be arranged relative to the drive mechanism so that the reinforcement elements may be moved in a selected direction while being guided by the gripping elements. This allows the tool to actively push the reinforcement elements into the assembly station.

[0035] Alternatively, the gripping elements may be arranged on the drive mechanism so that the gripping elements may be moved by the drive mechanism in a selected direction. Optionally, the drive mechanism may be configured to move the reinforcement elements in a first direction and to move the gripping elements in a second direction. The first and second directions may be the same or differ. This allows the tool to actively move the gripping elements into position relative to the loading end and / or the assembly station.

[0036] The drive mechanism may comprise rollers, an endless belt, wheels, or the like, for contacting the reinforcement elements. Optionally, a motor, e.g. an electrical motor, may be used to drive the rollers, the endless belt or the wheels, e.g. along a rail or track. The drive mechanism and / or the gripping elements may be operated via the control unit.

[0037] In one embodiment, the apparatus comprises a loading table arranged at the loading end, wherein the loading table is configured to store a plurality of reinforcement elements or sets of reinforcement elements.

[0038] The apparatus of the present invention may also comprise a loading table arranged at the loading end. The loading table may be configured to hold a plurality of the longitudinal reinforcement elements. The individual longitudinal reinforcement elements may be moved, manually or automatically, into a loading position, when needed. The loading table may further have a loading end for loading the longitudinal reinforcement elements onto the loading table. This allows the longitudinal reinforcement elements to be loaded all at once, or in batches, to allow for a continuous assembly process. In one embodiment, the loading table comprises at least one further tool configured to attach a number of reinforcement elements together to form a set of reinforcement elements, preferably the at least one further tool being configured to be attached to at least one robot arm of at least one robotic unit.

[0039] The loading table may be configured to allow two or more longitudinal reinforcement elements to be pre-assembled into sets. The loading table may comprise one or more tools configured to attach the respective reinforcement elements together. Optionally, the reinforcement elements may contact each other, or a number of spacers may be arranged in between the reinforcement elements. This allows for longitudinal reinforcement elements to be pre-assembled into sets extending in the width direction and / or in the height direction.

[0040] The tools may be configured to be operated manually by a worker. Alternatively, the tools may be attached to one or more local robotic units. The robotic unit may comprise at least one robot arm having a free end at which the tool is attached. The robotic units and / or the tools may be controlled via the control unit or a separate control unit. This allows for automatic assembly of the sets of reinforcement elements.

[0041] The sets of reinforcement elements may also be pre-assembled at other location and then loaded into the loading table.

[0042] One objective of the invention is also achieved by an assembly station, according to claim 9, for assembling a reinforcement cage, the assembly station comprises an assembly area extending in a longitudinal direction and in a transverse direction, the assembly station has a first feeding end for infeed of longitudinal reinforcement elements and a second feeding end for infeed of transverse reinforcement elements, the assembly station comprises supports and at least one conveyor unit, the supports being configured to receive and hold the transverse reinforcement elements, and the at least one conveyor unit comprising at least one guide element configured to guide the longitudinal reinforcement elements when fed into the assembly station, wherein the at least one conveyor unit further comprises a local lifting mechanism configured to move the reinforcement cage in a height direction.

[0043] This provides an assembly station capable of producing complex reinforcement cages.

[0044] The present assembly station is also capable of handling sets of reinforcement elements. This increases the functionality of the assembly station compared to other assembly stations using robotic units.

[0045] The assembly station has an assembly area extending in a longitudinal direction, a transverse direction and further in a height direction. The assembly station has a first feeding end for feeding longitudinal reinforcement elements into the assembly area. The assembly station further has a second feeding end for feeding transverse reinforcement elements into the assembly area. Optionally, the assembly station may also have an unloading end for removing the reinforcement cage from the assembly area.

[0046] Supports are distributed along the assembly area for receiving and holding the transverse reinforcement elements. The supports may be shaped as a single, continuous support structure extending in the longitudinal direction. Optionally, multiple support structures may be arranged relative to each other in the longitudinal direction. Each support structure may define a number of longitudinal positions for placement of the reinforcement elements. This allows the transverse reinforcement elements to be fixed in the longitudinal direction during the assembly process.

[0047] Conveyor units are further distributed along the assembly area for receiving and holding the longitudinal reinforcement elements. The conveyor units may be shaped as a single, continuous conveyor structure extending in the longitudinal direction. Optionally, multiple conveyor structures may be arranged relative to each other in the longitudinal direction. Each conveyor structure may be formed as a support arm or frame depending on the configuration of the assembly station. Each conveyor unit comprises one or more guide elements configured to guide the longitudinal reinforcement elements in the longitudinal direction. This allows the longitudinal reinforcement elements to rest on the conveyor units before being attached to the transverse reinforcement elements.

[0048] Further, the assembly station comprises one or more attaching units configured to fix the longitudinal and transverse reinforcement elements together along one or more attachment points. In the present invention the attaching units are robotic units, each with at least one robot arm having a free end. A welding or tying tool may be attached, permanently or via matching coupling elements, to the free end of the robot arm. The robotic units may be arranged on one or more rails or an overhead gantry system so that the robotic unit may be able to move along the X-, Y- and Z-axes, e.g. in the longitudinal direction, the transverse direction and / or the height direction. Various robotic units for fixing the longitudinal and transverse reinforcement elements together are known, however specially designed robotic units may also be used. This allows the reinforcement cage to be assembled using an automated process.

[0049] The operation of the assembly station may be controlled by a local control unit or the central control unit. The control unit may use sensors, cameras or a combination thereof to control the operation of the respective tools and / or the relative movement of the respective robotic units. The control unit may be capable of communicating with other control units, such as the control unit of the above apparatus.

[0050] Further, one or more of the conveyor units comprises a local lifting mechanism configured to move the reinforcement cage in a height direction. The local lifting mechanism is arranged relative to the guide elements on the conveyor structure. The local lifting mechanism may be configured to move the reinforcement cage in a distance between an installation height and an adjustment height. The distance may be preselected to allow adjustment of the guide elements.

[0051] In one embodiment, the at least one conveyor unit is connected to another lifting mechanism configured to move the reinforcement cage in the height direction.

[0052] The conveyor units may be connected to main lifting mechanism of the assembly station. The main lifting mechanism may be configured to move the conveyor units, and reinforcement cage, in the height direction during the assembly process. This allows the conveyor units to be moved between different installation heights relative to the reinforcement cage.

[0053] The local and main lifting mechanism may also be powered by a hydraulic, pneumatic or electrical power source.

[0054] In one embodiment, the at least one guide element is adjustable relative to at least the width or height of a selected reinforcement element or a set of reinforcement elements.

[0055] The guide elements may be adjustable in the width direction and / or height direction to adjust to the dimensions of the longitudinal reinforcement elements or sets thereof. The guide element may comprise two or more gripping fingers that may be moved or rotated relative to each other to adjust to the dimensions of the reinforcement elements or sets thereof. This allows the guide elements to grip the reinforcement elements when moving them into contact with the transverse reinforcement elements.

[0056] In one embodiment, the at least one guide element is configured to rotate the reinforcement elements into an installation angle relative to the reinforcement cage in the assembly station.

[0057] Further, the guide elements may be configured to rotate the longitudinal reinforcement elements or set thereof, when fed into the assembly station, into an installation angle before attachment. The installation angle may be determined based on the configuration of the reinforcement cage. The guide element may be rotated by means of actuators connected to the conveyor unit and to the guide element. This allows the reinforcement elements to be orientated correctly when assembling the reinforcement cage.

[0058] One objective of the invention is also achieved by a system, according to claim 13, comprising:

[0059] - an assembly station as described above,

[0060] - an apparatus as described above, the apparatus being arranged relative to the first feeding end of the assembly station,

[0061] - optionally, a first pre-assembly station configured to assembly sets of longitudinal reinforcement elements, the first pre-assembly station being arranged relative to the loading end of the apparatus, and

[0062] - optionally, a second pre-assembly station configured to assembly stirrups of transverse reinforcement elements, the second pre-assembly station being arranged relative to the second feeding end of the assembly station.

[0063] The present invention provides an apparatus and an assembly station that can interact with each other to produce complex reinforcement cages. The present system is capable of handling sets of longitudinal reinforcement elements and orientate them correctly during infeed into the assembly area. Further, the present system is also capable of handling stirrups of transverse reinforcement elements.

[0064] The above apparatus is arranged relative to the first feeding end of the assembly station for feeding longitudinal reinforcement elements into the assembly area. A pre-assembly station, e.g., a loading table, may be arranged relative to the loading end of the apparatus, where the longitudinal reinforcement elements may be assembled into sets before being fed into the assembly station. Further, another apparatus may be arranged relative to the second feeding end of the assembly station for feeding transverse reinforcement elements into the assembly area. A pre-assembly station or a loading table may be arranged relative to the apparatus, where the transverse reinforcement elements may be assembled into stirrups or be loaded into the apparatus before being fed into the assembly station.

[0065] The present system allows for a semi-automatic or fully automatic system for producing reinforcement cages. The present system is capable of handling longitudinal and transverse reinforcement elements with a diameter between 6-55 millimetres, preferably equal to or greater than 16 millimetres.

[0066] One objective of the invention is also achieved by a method of assembling a reinforcement cage, according to claim 14, comprising:

[0067] - loading transverse reinforcement elements into an assembly area of an assembly station via a second feeding end,

[0068] - loading longitudinal reinforcement elements into the assembly station via a first feeding end,

[0069] - attaching the longitudinal reinforcement elements to the transverse reinforcement elements along attachment points to form the reinforcement cage,

[0070] - wherein at least the longitudinal reinforcement elements are automatically fed into the assembly station using an apparatus arranged at the first feeding end, wherein the longitudinal reinforcement elements are picked up and fed into the assembly station using at least one robotic unit with at least one robot arm having a tool attached to a free end of the robot arm.

[0071] This provides an improved method of handling longitudinal reinforcement elements compared to other known methods. The present method is capable of handling sets of reinforcement elements and orientating them correctly relative to the reinforcement cage during infeed.

[0072] Longitudinal reinforcement elements are loading into the apparatus, which then feed them into the assembly station according to a predetermined order. The present method uses robotic units with tools to pick up the reinforcement elements and move them into an infeed position. The robotic units then push the reinforcement elements into assembly station via the tools and / or by movement of the robotic units. Transverse reinforcement elements are loading into the assembly station directly, or via another apparatus. The loading may be performed manually or by use of robotic units.

[0073] In one embodiment, a number of longitudinal reinforcement elements is pre-assembled into a set of reinforcement elements before being fed into the assembly station.

[0074] The individual longitudinal reinforcement elements may be pre-assembled into sets having a predetermined width and height. This may be performed manually or automatically using robotic units in a pre-assembly station. The pre-assembled sets of reinforcement elements may then be loaded into the assembly station via the apparatus. This reduces the amount of manual labour and reduces the risk of accidents.

[0075] Similarly, the individual transverse reinforcement elements may be pre-assembled into stirrups having a predetermined width and height. This may be performed manually or automatically using robotic units in a pre-assembly station. The pre-assembled stirrups may then be loaded into the assembly station manually or by one or more robotic units. This further reduces the amount of manual labour and reduces the production time.

[0076] In one embodiment, the set of longitudinal reinforcement elements is rotated into an installation angle relative to the reinforcement cage before being attached to the transverse reinforcement elements.

[0077] The present system may rotate the sets of longitudinal reinforcement elements before they are attached to the transverse reinforcement elements, e.g. by tying or welding. This may be performed in the above apparatus where the tool or robot arm are operated to rotate the set into an installation angle relative to the transverse axis. Alternatively, the guide elements in the assembly station may be operated to rotate the set before moving it into contact with the transverse reinforcement elements.

[0078] The set of reinforcement elements may be rotated into the correct installation angle by the apparatus. The guide elements in the assembly station may then be rotated to align them with the angle of the set. The set may then be pushed into the guide elements, which then moved the set into contact with the transverse reinforcement elements. Optionally, the assembly station may perform a further rotation of the set before moving the set into contact with the transverse reinforcement elements. Optionally, the guide elements and conveyor units may also be moved into an angled position in the transverse and / or height direction to correctly position the set or individual longitudinal reinforcement element relative to the transverse reinforcement elements. This may be performed after or before the longitudinal reinforcement element or set thereof may be pushed into the assembly station. This may be desired for very complex cage designs.

[0079] In one embodiment, the reinforcement cage is temporary moved in a height direction from an installation height to an adjustment height, while an adjustment of one or more attachment points of the transverse and longitudinal reinforcement elements are performed, afterwards the reinforcement cage is moved back into the installation height.

[0080] The conveyor units may be moved into an upper installation height where the longitudinal reinforcement element(s) may be fed into the guide elements at a first installation position. The longitudinal and transverse reinforcement elements are then attached together at a plurality of attachment points. The guide elements are then moved to another installation position along the conveyor unit, if necessary. Another longitudinal reinforcement element may then be fed into the guide elements and attached to the transverse reinforcement elements. This process may be repeated until all longitudinal reinforcement elements at the upper installation height are attached to the transverse reinforcement elements.

[0081] Optionally, the conveyor units may be moved into an adjustment height between infeed of longitudinal reinforcement elements to allow the guide elements to be moved between installation position along the conveyor units. This may be achieved by activating the local lifting mechanism on the conveyor units. Once the guide elements are moved from the one installation position and into another installation position, the next longitudinal reinforcement element may be fed into the guide elements. Afterwards the conveyor units may be moved back into the first installation height by deactivating the local lifting mechanism. The longitudinal reinforcement element may then be attached to the transverse reinforcement elements.

[0082] The conveyor units may subsequently be moved further into an intermediate installation height and the above attachment process is repeated. The conveyor units may then be moved to the next intermediate installation height. This may be repeated for all intermediate installation heights. Optionally, the partly assembled reinforcement cage may be moved out of the supports when at least two longitudinal reinforcement elements are attached to the transverse reinforcement elements. This may be achieved by further moving the conveyor units in the height direction so that the reinforcement cage may rest on the conveyor units. Thereby allowing the robotic units to easier move into position relative to the remaining attachment points between the longitudinal and transverse reinforcement elements. The reinforcement cage may then be moved into the adjustment height to allow the guide elements to be moved between installation positions on the conveyor units. A longitudinal reinforcement element may then be fed into the guide elements and the reinforcement cage may afterwards be moved back into the installation height. The longitudinal reinforcement element may subsequently be attached to the transverse reinforcement elements.

[0083] Once all longitudinal reinforcement elements may be attached at the respective intermediate installation heights, the conveyor units may then be moved into a lower installation height. The longitudinal reinforcement elements may then be attached in a process similar to that of the upper installation height.

[0084] Optionally, the reinforcement cage may be moved further in the height direction when at least two longitudinal reinforcement elements are attached to the transverse reinforcement elements. Thereby allowing the robotic units to easier move into position relative to the remaining attachment points between the longitudinal and transverse reinforcement elements. The reinforcement cage may be moved into the adjustment height to allow the guide elements to be moved between installation positions on the conveyor units. Once the guide elements are moved into another installation position and a longitudinal reinforcement element is fed into the guide elements, then reinforcement cage may be moved back into the installation height. This reduces the amount of movement of the reinforcement cage during assembly.

[0085] Once the assembly process is completed, then the reinforcement cage may be moved out of the assembly area via the unloading end. This may be achieved by an overhead crane system or a truck. The reinforcement cage is thus assembled using the robotic units in a semi-automatic or fully automatic process.

[0086] Description of the Drawing

[0087] Various examples are described hereinafter with reference to the figures. Like reference numerals refer to like elements throughout. Like elements will, thus, not be described in detail with respect to the description of each figure. It should also be noted that the figures are only intended to facilitate the description of the examples. They are not intended as an exhaustive description of the claimed invention or as a limitation on the scope of the claimed invention. In addition, an illustrated example need not have all the aspects or advantages shown. An aspect or an advantage described in conjunction with a particular example is not necessarily limited to that example and can be practiced in any other examples even if not so illustrated, or if not so explicitly described.

[0088] Exemplary embodiments of the invention are described in the figures, whereon:

[0089] Fig. 1 illustrates a system of the present invention,

[0090] Fig. 2 illustrates an exemplary embodiment of the apparatus for feeding longitudinal reinforcement elements into the assembly station,

[0091] Fig. 3 illustrates the apparatus of fig. 2 seen from the top,

[0092] Fig. 4 illustrates an alternative embodiment of the apparatus of fig. 2,

[0093] Fig. 5 illustrates an exemplary embodiment of the conveyor units with local lifting mechanisms,

[0094] Fig. 6 illustrates an exemplary embodiment of a reinforcement cage with sets of longitudinal reinforcement elements,

[0095] Fig. 7 illustrates a close-up of the guide elements on the conveyor unit relative to a set of longitudinal reinforcement elements.

[0096] Detailed Description of the Invention

[0097] Exemplary examples will now be described more fully hereinafter with reference to the accompanying drawings. In this regard, the present examples may have different forms and should not be construed as being limited to the descriptions set forth herein. Accordingly, the examples are merely described below, by referring to the figures, to explain aspects.

[0098] Throughout the specification, when an element is referred to as being “connected” to another element, the element is “directly connected” to the other element, “electrically connected”, “fluidic connected” or “communicatively connected” to the other element with one or more intervening elements interposed there between.

[0099] The terminology used herein is for the purpose of describing particular examples only and is not intended to be limiting. As used herein, the terms “comprises" "comprising" "includes" and / or "including" when used in this specification specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0100] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by those skilled in the art to which this invention pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined in the present specification.

[0101] Fig. 1 illustrates a system of the present invention comprising an assembly station 1 with an assembly area 2 extending in a longitudinal direction, a transverse direction and in a height direction. The assembly station 1 has a first feeding end 3 for feeding longitudinal reinforcement elements into the assembly station 1. Further, the assembly station 1 has a second feeding end 4 for feeding transverse reinforcement elements into the assembly station 1.

[0102] The assembly station 1 is configured to handle longitudinal rods and / or transverse rods having a diameter between 6-55 millimetres, preferably equal to or greater than 16 millimetres.

[0103] The assembly station 1 comprises one or more robotic units, each having at least one robot arm with a free end. A tool is permanently attached or attached via matching coupling elements to the free end of the robot arm. The robotic units are configured to move relative to the assembly area, e.g. along one or more rails. The tool may be a tying tool, a welding tool or a gripping tool, however other types of tools may also be used.

[0104] Further, the assembly station 1 comprises one or more supports 5 configured to receive and hold the transverse reinforcement elements in individual longitudinal positions. The assembly station 1 also comprises one or more conveyor units 6 configured to receive and hold the longitudinal reinforcement elements. The conveyor units 6 are connected to one or more main lifting mechanisms 7 configured to move the conveyor units 6 in the height direction. An apparatus 8, i.e. first apparatus, is arranged relative to the first feeding end of the assembly station 1. The apparatus 8 has a loading end and an infeed end, where the longitudinal reinforcement elements are loaded into the apparatus 8 via the loading end and fed into the assembly station 1 via the infeed end.

[0105] Another apparatus 9, i.e. second apparatus, is arranged relative to the second feeding end of the assembly station 1. The apparatus 9 has a loading end and an infeed end, where the transverse reinforcement elements, or stirrups, are loaded into the apparatus 9 via the loading end and fed into the assembly station 1 via the infeed end.

[0106] A control unit 10, such as a central control unit, is configured to control the operation of the assembly station 1 , the apparatus 8 and / or the apparatus 9. The control unit 10 may control the exchange of data between the assembly station 1 and the apparatuses 8, 9. The control unit 10 is configured to control the assembly process as well as the feeding process by transmitting control signals to the respective components in the assembly station 1 and the apparatuses 8, 9.

[0107] Fig. 2 illustrates an exemplary embodiment of the apparatus 8 for feeding longitudinal reinforcement elements 11 into the assembly station 1. Here, the apparatus 8 comprises a first robotic unit 12 and at least two second robotic units 13. The first robotic unit 12 comprises a first robot arm 14 with a free end, where a first tool 15 is attached to the free end. Each second robotic unit 13 comprises a second robot arm 16 with a free end, where a second tool 17 is attached to the free end.

[0108] The first robotic unit 12 is moveably arranged on a first rail 18 extending in a first direction, e.g. the transverse direction. The second robotic units 13 are moveably arranged on a common second rail 19 extending in a second direction, e.g. the longitudinal direction. The first and second robotic units 12, 13 may thus be moved relative to each other to pick up the longitudinal reinforcement elements 11 and moved them into their respective infeed positions at the infeed end.

[0109] A loading table 20 is arranged at the loading end and configured to hold a plurality of longitudinal reinforcement elements 11.

[0110] Fig. 3 illustrates the apparatus 8 seen from the top. A longitudinal reinforcement element 11 is moved to a loading position 21 where the first and second robotic units 12, 13 pick up the reinforcement element 11 via the first and second tools 15, 17. The first robotic unit 12 is arranged to move in the transverse direction 22 while the second robotic units 13 are arranged to move in the longitudinal direction 23. Thereby moving the reinforcement element 11 into its infeed position at the infeed end 24.

[0111] Fig. 4 illustrates an alternative embodiment of the apparatus 8 where only one second robotic unit 13 is arranged within the apparatus 8.

[0112] The second robotic unit(s) 13 is / are moved relative to the first robotic unit 12 to adjust the installation angle of the longitudinal reinforcement element 11 relative to the longitudinal axis 23. This is achieved by adjusting the second infeed position 24 at the second robotic units 13 relative to a first infeed position 25 at the robotic unit 12 in the transverse direction 22 and / or in the height direction 26.

[0113] Optionally, the longitudinal reinforcement element 11 is rotated 27 around a centreline into an installation angle relative to the transverse axis 22. This is achieved by rotating the robot arms 14, 16 and / or by rotating the tools 15, 17.

[0114] Once the tools 15, 17 are aligned with the guide elements on the conveyor units 6 and, optionally, the longitudinal reinforcement element 11 is orientated in the proper installation angle, then the longitudinal reinforcement element 11 is pushed into the assembly station 1 . Local drive mechanisms on the tools 15, 17 and / or the movement of the second robotic units 13 are used to push the longitudinal reinforcement element 11 in the longitudinal direction 23.

[0115] Fig. 5 illustrates an exemplary embodiment of the conveyor units 6 with local lifting mechanisms 28. The local lifting mechanisms 28 are configured to move the reinforcement cage 29 in the height direction 26 from an installation height to an adjustment height.

[0116] The first tool 15 comprises gripping elements 30 for gripping the longitudinal reinforcement elements 11. The gripping elements 30 are arranged on a local drive mechanism configured to move the gripping elements 30 along a rail 31. The position of the gripping elements 30 is adjusted by the drive mechanism so that the longitudinal reinforcement elements 11 is placed in the correct infeed position relative to the transverse reinforcement elements 32. Fig. 6 illustrates an exemplary embodiment of a reinforcement cage 29’ with sets 33 of longitudinal reinforcement elements. The sets 33 of longitudinal reinforcement elements are attached, e.g. tied or welded, to the transverse reinforcement elements 32 along individual attachment points.

[0117] Fig. 7 illustrates a close-up of the guide elements 34 on the conveyor unit 6 relative to a set 33 of longitudinal reinforcement elements. The guide elements 34 are adjustable in the width direction 35 gripping elements so that their inner width Wi is adjusted to the outer width W2of a selected reinforcement element 11 or a set 33 of reinforcement elements.

[0118] Optionally, the guide elements 34 are configured to rotate around a centreline to rotate the longitudinal reinforcement elements 11 , or sets 33 thereof, into a proper installation angle relative to the transverse axis 22. This is achieved by local actuators (not shown) arranged on the conveyor unit 6.

Claims

CLAIMS1. An apparatus (8) for feeding reinforcement elements (11 , 33) into an assembly station (1), the apparatus (8) defines an infeed end and a loading end, the comprising:- at least one feeding unit with at least one tool (15, 17) configured to pick up the reinforcement elements (11 , 33),- the least one feeding unit is configured to move the reinforcement elements (11 , 33) into an infeed position at the infeed end, the infeed position being aligned with a conveyor unit (6) in the assembly station (1),- wherein the feeding unit comprises at least one robotic unit (12, 13) with at least one robot arm (14, 16), where the tool (15, 17) is configured to be attached to a free end of the robot arm (14, 16), the robotic unit (12, 13) being configured to feed the reinforcement elements (12, 13) into the assembly station (1).

2. The apparatus according to claim 1 , characterised in that the at least one feeding unit is configured to move along at least one rail (18, 19) extending in at least a longitudinal direction (23) or transverse direction (22) of the apparatus (8).

3. The apparatus according to claim 1 or 2, characterised in that the apparatus (8) comprises a first robotic unit (12) and at least a second robotic unit (13), the first robotic unit (12) comprising first robot arm (14) with a first tool (15), and the second robotic unit (13) comprising second robot arm (16) with a second tool (17).

4. The apparatus according to 3, characterised in that the first and second robotic units (12, 13) are connected to a control unit (10), which is configured to operate the first and second robotic units (12, 13) in synchronisation or independently, preferably the first and second robotic units (12, 13) being configured to rotate the reinforcement elements (11 , 33) into an infeed angle relative to the reinforcement cage (29) in the assembly station (1) under control of the control unit (10).

5. The apparatus according to any one of claims 1 to 4, characterised in that the at least one tool (15, 17) comprises adjustable gripping elements (34) configured to be adjusted relative to the width W2 of a selected reinforcement element (11) or a set (33) of reinforcement elements.

6. The apparatus according to any one of claims 1 to 5, characterised in that the at least one tool (15, 17) comprises a drive mechanism configured to actively move thereinforcement element (11) or the set (33) of reinforcement elements in the longitudinal direction (23) and / or transverse direction (22).

7. The apparatus according to any one of claims 1 to 6, characterised in that the apparatus (8) comprises a loading table (20) arranged at the loading end, wherein the loading table (20) is configured to store a plurality of reinforcement elements (11) or sets (33) of reinforcement elements.

8. The apparatus according to claim 7, characterised in that the loading table (20) comprises at least one further tool configured to attach a number of reinforcement elements (11) together to form a set (33) of reinforcement elements, preferably the at least one further tool being configured to be attached to at least one robot arm of at least one robotic unit.

9. An assembly station for assembling a reinforcement cage (29), the assembly station (29) comprises an assembly area extending in a longitudinal direction (23) and in a transverse direction (22), the assembly station (1) has a first feeding end for receiving longitudinal reinforcement elements (11 , 33) and a second feeding end for receiving transverse reinforcement elements (32), the assembly station (1) comprises supports (5) and at least one conveyor unit (6), the supports (5) being configured to receive and hold the transverse reinforcement elements (32), and the at least one conveyor unit (6) comprising at least one guide element (34) configured to receive and guide the longitudinal reinforcement elements (11 , 33) when fed into the assembly station (1), wherein the at least one conveyor unit (6) further comprises a local lifting mechanism (28) configured to move the reinforcement cage (29) in a height direction.

10. The assembly station (1) according to claim 9, characterised in that the at least one conveyor unit (6) is connected to a main lifting mechanism (7) configured to move the at least one conveyor unit (6) in the height direction.

11. The assembly station (1) according to claim 9 or 10, characterised in that the at least one guide element (34) is adjustable relative to at least the width or height of a selected reinforcement element (11) or a set (33) of reinforcement elements.

12. The assembly station (1) according to any one of claims 9 to 11 , characterised in that the at least one guide element (34) is configured to rotate the reinforcementelements (11 , 33) into an installation angle relative to the reinforcement cage (29) in the assembly station (1).

13. A system comprising:- an assembly station (1) according to any one of claims 9 to 12,- an apparatus (8) according to any one of claims 1 to 8, the apparatus (8) being arranged relative to the first feeding end (3) of the assembly station (1),- optionally, a first pre-assembly station configured to assembly sets (33) of longitudinal reinforcement elements, the first pre-assembly station being arranged relative to the loading end of the apparatus (8), and- optionally, a second pre-assembly station (9) configured to assembly stirrups of transverse reinforcement elements (32), the second pre-assembly station (9) being arranged relative to the second feeding end (4) of the assembly station (1).

14. A method of assembling a reinforcement cage (29), comprising:- loading transverse reinforcement elements (32) into an assembly area of an assembly station (1) via a second feeding end (4),- loading longitudinal reinforcement elements (11 , 33) into the assembly station (1) via a first feeding end (3),- attaching the longitudinal reinforcement elements (11 , 33) to the transverse reinforcement elements (32) along attachment points to form the reinforcement cage (29),- wherein at least the longitudinal reinforcement elements (11 , 33) are automatically fed into the assembly station (1) using an apparatus (8) arranged at the first feeding end (3), wherein the longitudinal reinforcement elements (11 , 33) are picked up and fed into the assembly station (1) using at least one robotic unit (12, 13) with at least one robot arm (14, 16) having a tool (15, 17) attached to a free end of the robot arm (14, 16).

15. The method according to claim 14, characterised in that a number of longitudinal reinforcement elements (11) is pre-assembled into a set (33) of reinforcement elements before being fed into the assembly station (1).

16. The method according to claim 15, characterised in that the set (33) of longitudinal reinforcement elements is rotated into an installation angle relative to the reinforcement cage (29) before being attached to the transverse reinforcement elements (32).

17. The method according to any one of claims 14 to 16, characterised in that the reinforcement cage (29) is temporary moved in a height direction from an installation height to an adjustment height, while an adjustment of one or more attachment points of the transverse and longitudinal reinforcement elements (11, 32) are performed, af- terwards the reinforcement cage (29) is moved back into the installation height.

Images