EP0677343B1 - Method and apparatus to produce reinforcements for formworks - Google Patents

Abstract

The computer controlled machine has one station (12) that selects specific sizes of metal rod from a number of reels (16). The rod is straightened and located in guides and is cut to specific lengths. The rods pass on to an output bed and are transferred in sequence to a second unit (A) that forms the reinforcement mesh. This involves the welding of the bars to cross fed strip material (20). The strip is fed from a main supply roll (22) as a number of parallel strips. After passing through the welding stage the completed mesh is wound on to a roll (26). <IMAGE>

Description

The invention relates to a method for producing individual reinforcements for reinforced concrete surface structures, the reinforcement having at least one rod mat to be rolled out in one direction on the construction site with flexible strips running in the roll-out direction and rods fastened at right angles thereto and at least one second rod mat rolled out at right angles to the first rod mat , the bars of which lie loosely on the bars of the first bar mat which cross them, and the strips are fitted with the bars in a mat assembler and the mat is wound up into a roll.

Such a method is known from US-A-3797193. It streamlines production and reduces the amount of steel normally used for reinforcement, but this proposal is not suitable for the fully automatic production of individual reinforcement meshes, which can have reinforcement bars in a large diameter range.

A CAD system from Nemetschek Programm System GmbH, Munich, is known under the name ALLPLOT, which has a program that creates reinforcement lists and plans corresponding to the structural conditions of the building. In addition to the current member number, the file contains the diameter and length of the member. This program can be used for beam reinforcement, but not for tensile structures, because additional dimensions would have to be added here. This program accelerates the creation of reinforcement plans and lists. However, this program has no influence on the manufacture of the reinforcement itself.

Machines for the automatic production of reinforcement meshes are also known, e.g. from DE-A-36 15 460, but only standardized prefabricated ceilings can be produced with it. The control requirements for the production of individual reinforcement mats are missing.

The object of the invention is to create a new manufacturing method for individual reinforcements which, based on computational data of an extended structural analysis computer program, allows a fully automatic production of reinforcement meshes without any manual keyboard input of data and mechanical interventions.

This object is solved by the features of claim 1.

The computer program available to the structural engineer, e.g. The aforementioned ALLPLOT program only needs to be expanded in such a way that, in addition to the characteristic member data, it also determines the position data of the members per mat layer. According to the finite element method, depending on the input of any static system, both the bar-specific and the mesh-specific values of all bars of the two lower and the two upper bar positions of the reinforcement are calculated. In this case, particularly in the case of surface structures, these values are often unequal on a limited area unit, the bars or bar groups being able to differ in length, thickness, longitudinal position and mutual distance. The method according to the invention leads to a fully automatic production of the reinforcement mesh. Thanks to the individual production, a considerable reduction in the amount of structural steel is achieved.

In the simplest case, the invention only requires two machines which operate under computer control, namely a bar former and a mat assembler. Both machines have a length equal to the maximum bar length of, for example, 15 m. A rod mat roll with a length of 15 m can be easily transported in road traffic. Wire coils or wire magazines for the bars are connected upstream of the bar former.

Controlled by the program module, the rod generator ejects the rods selected in terms of length and diameter. These rods still have to be moved into the correct longitudinal position for the later rod mat. This can be done outside the staff. According to a variant of the invention, this longitudinal sliding device for the bars is assigned to the mat assembler.

A further development of the invention is that the tapes are designed to be resilient. It has proven to be practical to use narrow steel strips, such as those used for packaging purposes. These have sufficient resilience. The torque required for rolling out the mats on the construction site is provided according to the invention at least in part by the spring forces of the belts stored in the rod mat roll. The spring strength of the tapes can be chosen so large that a slight push is sufficient to achieve a self-unrolling even with thick rod mat rolls.

Two possibilities for operating the assembler are within the scope of the invention. One possibility is to drive the belts intermittently and to connect them to the bars during the idle periods. The alternative is to let the tapes run continuously, the rod connecting members being moved with the tapes in a forward stroke during the joining process and performing their return stroke to the starting position after the joining process has ended.

Since universal use of the method according to the invention presupposes that rods in the diameter range from 5 mm to 28 mm can be present in one and the same mat, the binding method for fastening the rods to the belts is selected according to one embodiment of the invention. Wire is used as a binding agent. At each point of intersection of the rod with a band, a wire connector is arranged above the rod and below the band. The wire connectors alternately shoot lengths of wire into one another's receiving funnel Wire connector. Then the rotating heads of the wire connectors are set in rotation, whereby the rod is tied to the tape. The shooting-in process and the twisting process are independent of the rod diameter, so that the fastening time is the same for all rod diameters.

An important development of the method according to the invention can still be seen in the fact that the rod mat roll is produced without a core, that is to say without a winding mandrel. The entire rod mat roll can thus be processed at the construction site without any remaining objects, so that the transport of reusable return parts is saved. This is achieved in that the strips each have a leading section which is deformed into a winding ring in the winding station, so that the first reinforcing bar meets the circumferentially closed winding rings formed by the strips. In order to stabilize these wrapping rings, it is advisable to profile the tape feed sections, for example to give them a V cross-section. Because of this deformation, there is the advantage of an additional form-fitting guide in the guide rollers or the guide bands of the winding station.

An alternative or cumulative feature according to the invention is that at least two wire rings are welded to the first rod of the rod mat before the winding process in the longitudinal distance, which act as a winding core during the subsequent winding of the mat and are simply broken off at the construction site.

The invention further relates to a machine for the production of bar mat rolls for the reinforcement of reinforced concrete surface structures, the bar mat to be wound up consisting of flexible parallel bands and bars held thereon, with a conveyor device which feeds the bars to a longitudinal sliding device, from which the bars arrive at a mat assembler , which has a number of tape supply rolls arranged at intervals, of which the tapes lead parallel to winding rolls of a winding device and the longitudinal sliding device has a roll bed, the rolls with axes parallel to each other and to the tapes each arranged between two belts and aligned along a line perpendicular to the belts and the rollers are at least approximately V-shaped in cross section and at least one of the rollers is coupled to a drive motor which forms the drive of the longitudinal sliding device.

Such a machine is known from the aforementioned US-A-3797193. In this known machine, the bars are each arranged between lower and upper metal strips. The upper metal bands are looped around the bars and welded to the lower bands. so that tape loops are formed in which the rods are slidably supported longitudinally. The bars can therefore be shifted relative to each other at the construction site and even pulled out completely to take account of the given static conditions. The mats produced in this way are therefore standard mats which are only adapted to individual requirements on the construction site. From the drawing of this document it can be seen that the rods are of equal length and are also positioned on the strips at equal intervals. The individual adjustment of the reinforcement mat on the construction site is labor intensive, imprecise and involves the risk of reinforcement errors.

The machine according to the invention differs from this prior art in that a known static CAD program, which calculates the reinforcing bars of a bar mat with the initial data: sequence number, thickness and length from the static conditions of the structure, is expanded in that it determines the distance from the previous bar and the distance of a bar end from an imaginary mat edge as additional position data, that a transformation program in a computer converts the output data and the position data of the CAD program into a machine control program or several program modules that the longitudinal sliding device Computer-controlled rod former is connected upstream, which, depending on the program module containing the transformed output data, wire winding or wire magazine from Select wires of the appropriate diameter, unwind or pull the wires and, if necessary, cut them to predetermined lengths after straightening to form the bars, that the bars are successively shifted by means of a longitudinal sliding device into predetermined longitudinal positions with respect to the mat assembly, the drive of the longitudinal sliding device being controlled by the, at least part of the transformed position data-containing program module is controlled, and that the belts in the mat assembler are guided in a single belt running plane and are equipped on one side with the bars in such a way that they are attached to the belts in a relatively immovable manner in their longitudinal positions caused by the longitudinal sliding device.

An advantageous development of the machine according to the invention is achieved with the features of claim 8. For a maximum mat width of 15 m, for example, 11 belts with a respective spacing of 1.50 m are provided. The machine modules can, for example, have a width of 0.2 m up to a belt spacing of 1.50 m. All modules are the same and interchangeable. The frames can be rigidly connected to one another by mechanical connecting links. In the same way, it is possible to mechanically connect the drive shafts of the tape feed devices of all modules to one another by connecting shafts by means of shaft couplings, so that a single drive motor is sufficient for all drive rollers of the tape feed device for the tapes. The same applies to the drive shafts of the winding device. Each module is thus assigned to one of the tapes or a group of tapes.

The drawing, which shows exemplary embodiments of the invention, will be used to describe it.

FIG. 1

eine Ansicht einer Fertigungsmaschine für Bewehrungen mit einem Stabbildner und einem Mattenkonfektionierer,

FIG. 2

ein Flußdiagramm zur Erzeugung der Steuersignale für die einzelnen Antriebe der Herstellungsmaschine,

FIG. 3

eine schematische Seitenansicht einer Ausführungsform des Mattenkonfektionierers,

FIG. 4

eine Seitenansicht des Mattenkonfektionierers mit Stabzufuhreinrichtung und Stablängsschiebeeinrichtung,

FIG. 5

eine Vorderansicht des Konfektionierers mit Darstellung der Modulbauweise der Maschine, wobei jedem der Vielzahl an Bändern ein eigenes Maschinenmodul zugeordnet ist,

FIG. 6

eine vergrößerte Ansicht der Figur 5,

FIG. 7

eine Detailansicht für die bewegbare Lagerung der Stäbe im Konfektionierer,

FIG. 8

eine Seitenansicht einer abgewandelten Ausführungsform des Mattenkonfektionierers,

FIG. 9

eine Schnittansicht längs der Linie A-A der Figur 8, und

FIG. 10

eine schematische Detailansicht eines Drahtverbinders zum Verbinden eines Stabes an einem Band.

It shows:

FIG. 1

1 shows a view of a reinforcement production machine with a bar former and a mat assembler,

FIG. 2nd

1 shows a flowchart for generating the control signals for the individual drives of the production machine,

FIG. 3rd

2 shows a schematic side view of an embodiment of the mat assembly,

FIG. 4th

a side view of the mat assembler with bar feed device and bar longitudinal sliding device,

FIG. 5

2 shows a front view of the assembler showing the modular construction of the machine, with each of the plurality of belts being assigned its own machine module,

FIG. 6

5 shows an enlarged view of FIG. 5,

FIG. 7

a detailed view for the movable storage of the bars in the assembly,

FIG. 8th

a side view of a modified embodiment of the mat assembler,

FIG. 9

a sectional view taken along line AA of Figure 8, and

FIG. 10th

a schematic detailed view of a wire connector for connecting a rod to a tape.

The machine, generally designated 10, for producing wound reinforcement mats comprises a bar former 12 and a mat assembler 14. The bar former 12 is preceded by a supply station in which a number of wire rolls 16 is rotatably arranged, on which the wires of different diameters for the reinforcement bars are wound. Such rod formers are known and therefore do not need to be described in detail. Program-controlled, one of the wires is drawn into the rod former 12, straightened and cut to length. The bars 18 leave the bar former 12 via a slide and can be fed to the mat assembler 14 either directly or by means of a transfer device (not shown).

Thicker bars 18 are obtained from magazines with straight bar blanks, e.g. butt welded to length in the rod former.

The mat assembler has a number of parallel metal strips 20, which are guided from supply rolls 22 via deflection rolls 24 to winding devices 26. Each band 20 is guided horizontally in the area of a rod connecting device 28 between two deflection rollers 24, a deflection roller located directly in front of the winding device 26 having been omitted in FIG. 1. All deflection rollers 24 located to the left of the connecting device 28 are aligned coaxially. The same applies to the right-hand deflection rollers, not shown. A horizontal belt running plane is defined between this roller arrangement. The rod connection device 28 according to FIG. 1 comprises, for each band 20, a welding electrode 30 which can be driven up and down below the band running plane and a counter electrode 32 arranged above welding electrodes 30 on a continuous rail or a hinged bracket 64 (Figure 8). Between each two lower welding electrodes 30 there are profiled rollers 34, which result in a roller bed directed at right angles to the direction of strip travel, into which the rods arrive on a slide 36 (FIGS. 3, 4). Stop flaps 38 stop the rods 18 from sliding down on the roller bed. At least one of the rollers 34 has a drive 40 which represents a longitudinal sliding device for the rod 18 in order to bring it into the desired position transversely to the longitudinal direction of the mat. When this is reached, the lower welding electrodes 30 move upwards and press the rod 18 with the adjacent band sections of the bands 20 against the upper welding bar 32, so that the rod 18 is welded to the bands 20 at the crossing points.

In order to position the next bar 18 at the correct distance from the previous bar on the belts 20, the machine 10 has a belt feed device 42 which consists of a motor-driven roller which forms a narrow running gap for the belt 20 with the upper deflection roller 24. The drive motor of the tape feed device 42 is a stepper motor which, under program control, brings about the required feed length of the tapes 20 and then stops the tapes. The winding devices 26 keep the tapes 20 running from the feed device 42 sufficiently taut. The feed device 42 thus acts as a brake.

As is apparent from Fig. 1, each tape reel is supported in the winder 26 on a number of driven rollers. The support rollers for the tape reel cause a higher peripheral speed than the tape speed controlled by the tape feed device 24, even with a small winding diameter of the tape reel. The tape rolls thus slip through on the support rollers of the winding device 26.

The control of the drives of the machine 10 will now be described in connection with FIG. 2. A structural analysis computer program 44 generates a special file 45, corresponding to the respective static requirements of a tensile structure, with the corresponding values for the bending reinforcement. This file 45 is formatted by a transformation program 46 in such a way that the required data 47 for several program modules result, which are analogous to a reinforcement plan. The program data 47 are stored on a floppy disk 48. Three program modules 50, 52, 54 are stored on diskette 48. The program module 50 contains the rod-specific output data of the rods 18 to be fastened one after the other, namely the order, the length and the diameter of the respective rod 18. The program module 52 contains position control data for the longitudinal positions of the successive rods 18 on the mat to be produced and the program module 54 the position control data for the distance of the respective bar from the previous bar. The control data of the program module 50 are converted in the computer into control signals for the drives in the rod former 12 and transmitted to the rod former 12 via a cable 51. Control signals are generated from the program data of the program modules 52, 54 in the same computer or in a computer assigned to the mat assembler 14, which control the longitudinal sliding drive 40 and the belt feed device 42 via lines 53, 55. The welding bar 32 receives welding current over the line 57 as a function of the tape feed 42, which ensures that the downtimes of the tapes 20 are matched to the necessary welding time by appropriate control of the tape feed device 42, which is dependent on the diameter of the rods 18 and on average is about 4 seconds. Therefore, the electrodes of the welding bar 32 are supplied with control signals which contain the diameter data of the rods 18 and the position data from the Take the longitudinal sliding device 40 into account in order to activate only those welding electrodes at the actual crossing points of the rod with the strips.

Alternatively, the control signals for controlling the drives 12, 40 and 42 can also be generated by the program 46.

From the above description it follows that all the characteristic data 47, which can also be fed directly to the computer in the iron bending shop via a network, control the drives of the rod former 12 and the mat assembler 14 without any keyboard inputs and further interventions, so that the individual one after the other fully automatically Reinforcement mats can be made for reinforcement.

FIGS. 5-10 show another exemplary embodiment, in which the mat assembler 14 is composed of a number of identical machine modules 15, which can be moved on wheels and are close to one another in the exemplary embodiment. Each machine module 15 processes one of the metal belts 20. The bars 18 pass from the bar former 12 via individual slide rails 36 to the modular assembly machine 14. Laterally offset from the vertical running plane of a belt 20, a profiled roller 34 is arranged in each machine module 15. At least one of these rollers 34 has the longitudinal slide drive 40 or the longitudinal slide drives 40 of all machine modules 15 are electrically connected to one another, but could also be mechanically coupled and run synchronously. Each machine module 15 has a plurality of tape supply rolls 22 which can be rotated next to one another on a common shaft, so that when a roll 22 is used up, the expired end of the tape can be mechanically connected to the start of the tape of the adjacent roll, for example by means of a hook-and-eye connection. The slide rails 36 have a number Locking levers 37, which form a buffer for a number of rods 18. A storage compartment for a single rod 18 is formed between two locking levers 37. Program-controlled, the locking levers 37 are briefly opened one after the other while the tape feed device 42 is being driven, so that the bottom bar 18 reaches the rollers 34 of the roller bed and the bars 18 lying above slide into the respective compartment below. Since the rollers 34 hold the rod 18 above the strip running plane, the rod longitudinal slide device 40 can now bring the rod into the longitudinal position even before the strip feed 42 stops. Once the correct distance from the preceding rod has been established, the belts 20 are briefly stopped and the rod connecting devices 28 come into action. According to FIG. 10, these consist of two wire connector assemblies 80, 82. The wire connector 80 has a built-in wire feed, which coaxially shoots out a certain wire length 84 from a rotary head 86. The wire front end comes into a deflection groove of the upper assembly 82, which bends the wire and presses it into a funnel-shaped hole 88 in the rotary head 86. The rotary head 86 then rotates a few turns until the wire loop is firmly closed at the point of intersection between rod 18 and band 20 and shears off.

As an alternative to the wire connector shown in FIG. 10, this can have two identical wire connection units on both sides of the strip running plane, which interact with one another. Each unit then shoots the same length of wire in a straight line into the narrowing hole of the turret of the opposite unit and the turrets of both units then rotate to cause an upper and a lower twist.

7, the rollers 34 with their drives 40 can be lowered below the running plane of the belts 20 by means of suitable actuating cylinders 60. The rod 18 will then placed on the belts 20 and moved by these in the longitudinal direction of the mat. The wire connection units 80, 82 can also be moved for the duration of the connection action with the bands 20, for which purpose they are arranged pivotably about the axis 92. Thanks to time synchronization, the intermittent operation of the tape feed device can be replaced by a continuous operation. The bar spacing is then controlled by the time lowering intervals of the rollers 34, so that the longitudinal sliding device 34, 40 also takes over the positioning function with its lifting / lowering drive.

According to FIG. 8, the upper wire connection unit is fastened to a swivel arm 64 which engages over the winding station 26. However, these units can also be connected to the lower wire connecting unit via a strap which bypasses the band 20.

8 has two bottom support rollers 66 for the rod mat roller 68, one of which is driven by a motor. Furthermore, an upper stationary deflection roller 69 and a pivotable deflection roller 70 are provided and the four rollers 66, 66, 69, 70 are wrapped in a belt loop 72 which surrounds the bar mat roller 68 over a considerable part of its circumference. The pivot arm of the roller 70 is resiliently biased counterclockwise and takes the dashed position at the beginning of the winding process. The roller 70 then presses on the initial winding of the band 20 and holds it in positive engagement with a V-shaped groove 74 of the band loop 72. The leading portions of each band 20 are also V-shaped by means of a profiling device, not shown, so that they are in the grooves 74 can intervene positively. This deformation of the tape leader sections over a length equal to the initial one The winding diameter simultaneously stabilizes the rings, so that the individual band rings form a replacement for a winding core of the rod mat roll 68.

Claims (10)

1. A process for producing individual reinforcements for plane reinforced-concrete load-bearing structures, where the reinforcement includes at least one bar mat which is to be rolled out in one direction on the building site and has flexible bands (20) running in the rolling-out direction and bars (18) fastened to the latter at right angles, and at least one second bar mat which is rolled out thereabove at right angles to the first bar mat and whose bars (18) rest loosely on the bars (18) of the first bar mat which intersect them, and where the bands (20) are fitted with the bars (18) in a mat maker (14) and the mat is wound up to form a roll, characterised in that

   a) a statics CAD program, which is known per se and from the static conditions of the load-bearing structure calculates for the reinforcement bars (18) of a bar mat the initial data: serial number, thickness and length, is extended in that it determines for each bar (18) the spacing from the previous bar (18) and the spacing of a bar end from an imaginary mat edge as additional positional data, and in that the initial data and the positional data of the CAD program are converted into a machine control program or a plurality of program modules (50, 52, 54) by means of a transformation program in a computer, in that

   b) a computer-controlled bar former (12) selects wire reels or wire magazines with wires of appropriate diameters in dependence on the program module (50) containing the transformed initial data, reels off or draws off the wires and, if necessary after straightening, cuts them off to preset lengths to form the bars (18), in that

   c) the bars (18) are successively displaced into preset longitudinal positions with respect to the mat maker (14) by means of a longitudinal pushing device (34, 40), the drive (40) of the longitudinal pushing device being controlled by the program module (52) containing at least a part of the transformed positional data, and in that

   d) the bars (18) are fastened non-displaceably to bands (20), running transversely to them, of the mat maker (14) at spacings controlled by the transformed positional data of the or a program module (54).
2. A process according to Claim 1, characterised in that spring-steel material is used for the bands (20) and the torque necessary for the rolling-out of the bar-mat rolls (68) on the building site is provided at least partly by the spring forces, stored in the bar-mat roll (68), of the hands (20).
3. A process according to Claim 1 or 2, characterised in that the bands (20) are driven intermittently and are connected to the bars (18) during the stationary periods.
4. A process according to one of Claims 1 to 3, characterised in that the bar-mat roll (68) is wound up without a core by each band (20), consisting of metal sheet, producing a band ring at a band leader in a winding-up device (26) before the first bar (18) connects the band rings to one another.
5. A process according to Claim 4, characterised in that the bands (20) are stiffened at least in the region of their initial band rings by cross-sectional deformation.
6. A machine for producing bar-mat rolls for the reinforcement of plane reinforced-concrete load-bearing structures, where the bar mat which is to be wound up comprises flexible parallel bands (20) and bars (18) secured to the latter, having a conveying device which feeds the bars (18) to a longitudinal pushing device (34, 40), from which the bars arrive at a mat maker (14) which includes a number of band supply rolls (22) arranged at intervals, from which the bands (20) run parallel to one another to winding rollers of a winding-up device (26), and the longitudinal pushing device (34, 40) includes a roller bed whose rollers (34) are arranged in each case between two bands (20), with their axes parallel to one another and to the bands (20), and are aligned along a line running at right angles to the bands (20), and the rollers (34) have an at least approximately V-shaped profile in cross-section and at least one of the rollers (34) is coupled to a drive motor (40) forming the drive of the longitudinal pushing device (14) [sic], characterised in that

   a) a statics CAD program, which is known per se and from the static conditions of the load-bearing structure calculates for the reinforcement bars (18) of a bar mat the initial data: serial number, thickness and length, is extended in that it determines for each bar (18) the spacing from the previous bar (18) and the spacing of a bar end from an imaginary mat edge as additional positional data, and in that a transformation program in a computer converts the initial data and the positional data of the CAD program into a machine control program or a plurality of program modules (50, 52, 54), in that

   b) there is arranged upstream of the longitudinal pushing device (34, 40) a computer-controlled bar former (12) which selects wire reels or wire magazines with wires of appropriate diameters in dependence on the program module (50) containing the transformed initial data, reels off or draws off the wires and, if necessary after straightening, cuts them off to preset lengths to form the bars (18), in that

   c) the bars (18) are successively displaced into preset longitudinal positions with respect to the mat maker (14) by means of the longitudinal pushing device (34, 40), the drive (40) of the longitudinal pushing device being controlled by the program module (52) containing at least a part of the transformed positional data, and in that

   d) the bands (20) are guided in a single band running plane in the mat maker (14) and are fitted with the bars (18) on one side in such a way that in their longitudinal positions brought about by the longitudinal pushing device (34, 40) they are fastened relatively non-displaceably to the bands.
7. A machine according to Claim 6, characterised in that the rollers (34) guide the respective bar (18) at a level above the band running plane and can be lowered to a level below this plane.
8. A machine according to Claim 6 or 7, characterised in that each of the bands (20) is assigned a band supply roll (22), a band-advancing device (42), a bar-connecting device (28) and a winding-up device (26), and in that these devices are arranged in their own machine frame (15), in that a number of frames (15) at most equal to the number of bands (20) are placed side by side, aligned flush, in a modular design, and in that the drives of the machine modules (15) thus formed are synchronised with one another.
9. A machine according to one of Claims 6 to 8, characterised in that the bar winding-up device (26) includes, as seen in the direction of the winding axis, at least two supporting rollers (66), at least one of which is drivable and transmits a turning force via its periphery to the bar-mat roll (68).
10. A machine according to one of Claims 6 to 9, characterised in that the band-advancing device (42) is arranged upstream of the bar-connecting device (28) and exerts a tensile force on the band portions which follow in the band running direction and lead to the winding-up device (26), the tensile force acting counter to the running direction, in that the winding-up device (26) attempts to drive the bands (20) at a speed greater than their desired speed and a slip connection is provided between the bands (20) and the drive of the winding-up device (26), the band-advancing device (42) having a braking effect, at least at time intervals, on the band portions leaving it, and in that the band-advancing device (42) includes drive means drivable by control signals of the program module (53) of a computer to reset the bar spacing from bar (18) to bar (18).

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