Reinforcement Cage Jig With Trolley Alignment for Faster Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional process of assembling a reinforcement cage is complex, time-consuming, and requires significant manpower and material resources due to the need for manual calibration and balancing of main bars and stirrups.
Innovation Solution
A jig comprising a base member with rollers, a movable trolley, a driving device, and main bar positioning members is used to streamline the assembly process by allowing the automatic alignment and installation of main bars into spiral stirrups, reducing the need for manual labor and resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual calibration and balancing of main bars and stirrups is used, then the reinforcement cage can be assembled, but the process becomes complex and time-consuming requiring significant manpower and material resources
Solution Approach 1:
The patent introduces a positioning device as an intermediary tool between the main bars and stirrups. This device includes positioning plates with through-holes that fit over the main bars, and positioning grooves on the stirrups that receive the positioning plates. This intermediary positioning mechanism automatically aligns and secures the stirrups to the main bars without requiring manual calibration or balancing, thereby simplifying the assembly process while maintaining manufacturing efficiency
Solution Approach 2:
The positioning device is segmented into multiple independent components: positioning plates, positioning grooves, and fixing members. Each component performs a specific function - the positioning plates provide alignment references, the grooves receive and constrain the plates, and the fixing members secure the assembly. This segmentation allows for easy assembly and disassembly while eliminating the need for complex manual calibration procedures
2Ease of manufacture
If manual calibration and balancing of main bars and stirrups is used, then the reinforcement cage can be assembled, but significant manpower and material resources are required
Solution Approach 1:
The positioning device serves as a reusable intermediary tool that eliminates the need for multiple manual calibration operations. By providing a standardized positioning mechanism with plates and grooves, the system reduces the quantity of manpower required as workers simply need to install the positioning devices rather than manually calibrate each connection. The positioning devices can be reused across multiple assembly operations, reducing overall material consumption compared to single-use manual calibration methods
3Productivity
If automated positioning and installation system is used, then the time and resources required for manufacturing are reduced, but the device complexity increases
Solution Approach 1:
The positioning device is divided into simple, modular segments: positioning plates with through-holes, stirrup positioning grooves, and fixing members. Each segment is a simple component that can be easily manufactured and assembled. The modular nature allows the system to achieve automated positioning functionality without requiring a complex monolithic structure, thereby maintaining high productivity while controlling device complexity
Solution Approach 2:
The positioning device uses standardized positioning plates that can be replicated and used across multiple stirrups and main bars. The through-holes in the plates and the corresponding grooves create a repeatable positioning pattern that can be copied throughout the reinforcement cage assembly. This standardization allows automated positioning without requiring complex custom-designed components for each connection point
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces the time and resources required for manufacturing a reinforcement cage by enabling efficient and automated alignment and installation of main bars within stirrups, thereby simplifying the assembly process.
Implementation Method 1
a plurality of rollers disposed on the base member and spaced at intervals; a trolley movable on the base member by the rollers
Data Source
AI summary
The present disclosure relates to a jig for manufacturing a reinforcement cage, which comprises a base member, a plurality of rollers disposed on the base member and spaced at intervals, a trolley which is movable on the base member; a driving device for driving the trolley; and a member for positioning the main reinforcement disposed at the first end of the base member.