On-Site Reinforcement Cage Assembly With Carrier and Attachment Robots
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Solution Overview
Problem
The existing methods for producing large reinforcement cages are inefficient and prone to errors due to manual assembly and transportation challenges, making it difficult to create cages of significant size for construction sites without extensive manual labor and high error rates.
Innovation Solution
An automated system comprising a reinforcement bar provider, carrier robots, and an attachment robot, which uses pre-cut and pre-bent reinforcement bars or rolls, allowing for precise planning and on-site assembly, reducing human error and increasing efficiency by using robots to arrange and attach bars according to pre-defined information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly methods are used to produce reinforcement cages, then flexibility in production location is maintained, but productivity is low and error rate is high
Solution Approach 1:
The system enables self-service production by providing an automated assembly arrangement that can operate independently at the construction site. The control unit processes reinforcement cage information and automatically controls the assembly process, eliminating the need for manual labor while maintaining production flexibility.
Solution Approach 2:
Manual mechanical assembly operations are replaced by an automated control system. The control unit receives reinforcement cage information and automatically controls the assembly process, substituting human mechanical operations with automated mechanical and computational systems.
2Length of stationary object
If large reinforcement cages are produced in a factory, then production quality can be controlled, but transportation to building sites becomes difficult or impossible
Solution Approach 1:
The reinforcement cage production process is segmented into two phases: component preparation at the factory and final assembly at the construction site. This allows large cages to be produced by assembling smaller components on-site, avoiding transportation difficulties while maintaining quality control through standardized components.
Solution Approach 2:
The problem is solved by changing the dimension of assembly from centralized factory production to distributed on-site assembly. Instead of transporting complete large cages, the system enables assembly at the destination location, effectively removing the transportation constraint.
3Ease of operation
If smaller reinforcement cages are produced for easy transportation, then transportation is simplified, but the need for multiple cages increases construction time and complexity
Solution Approach 1:
Reinforcement cage components are prepared in advance at the factory with predefined dimensions and bends, then transported to the construction site for rapid assembly. This preliminary preparation reduces on-site assembly time and eliminates the need for multiple separate cage installations.
4Productivity
If manual arrangement and attachment of reinforcement bars is performed, then adaptability to different cage designs is maintained, but the process is time-consuming and error-prone
Solution Approach 1:
The control unit receives reinforcement cage information and uses this data to automatically control the assembly process. This feedback mechanism ensures accurate placement and attachment of reinforcement bars according to the specified design, eliminating manual errors while maintaining adaptability to different cage configurations.
Data Source
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AI summary
The present invention relates to an arrangement and method for producing a reinforcement cage (100). The arrangement (1000) comprises: a control unit (700), and an assembler (500), the control unit (700) being arranged to provide reinforcement cage information relating to at least one from the group of position, order, and dimension of reinforcement bars in said reinforcement cage (100), and the assembler (500) being arranged to assemble reinforcement bars in accordance with said reinforcement cage information, thus producing said reinforcement cage (100).