Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
  • B21F—WORKING OR PROCESSING OF METAL WIRE
  • B21F27/00—Making wire network, i.e. wire nets
  • B21F27/12—Making special types or portions of network by methods or means specially adapted therefor
  • B21F27/20—Making special types or portions of network by methods or means specially adapted therefor of plaster-carrying network

Definitions

• the invention relates to the preparation and assembly of elements of metal reinforcements for the reinforcement of construction elements or of products which it is desired to produce in so-called reinforced concrete.
• the structure of a structure to be produced is conventionally the subject of a study by a design office which determines, in particular as a result of resistance calculations of the materials, the characteristics (constitution and geometry) of the framework ( therefore reinforcements) to be integrated into each element (panel, slab, pre-slab, etc.) of the structure. These characteristics are notably materialized by a design plan.
• the basic elements of a reinforcement are concrete rods of various diameters, and the design of the reinforcement of the flat elements to be made of reinforced concrete can provide for the use of a wide variety of such concrete rods to allow a suitable reinforcement of each zone of each planar element (for example, it is easily understood that in a vertical panel the reinforcement must be greater above the opening of a door than in a solid zone without opening).
• this reinforcement in each zone must be sufficient to guarantee good mechanical strength, but with a sufficiently moderate safety coefficient not to correspond to an unnecessary excess of reinforcement.
• this need for reinforcement exists in principle differently in various directions of an element. any plane (for example along the horizontal and vertical directions of a vertical panel).
• Optimal reinforcement of a given planar element therefore justifies choosing types, diameters, numbers and spacing of concrete rounds that can vary significantly from one area to another.
• the reinforcing elements are placed and assembled on site, in the formwork to receive the concrete or in the immediate vicinity thereof, using a plan on a reduced scale supplied to the reinforcement team leader.
• the position of the reinforcements is identified by transferring the dimensions of the plans using meters or decameters, then materialized by manual tracing using industrial chalks.
• the reinforcement element is complex, it is sometimes carried out a sketch on a concrete area, representing the characteristic points of the formwork.
• the reinforcements are produced using prefabricated pieces of reinforcement which, after cutting, are placed on the part of the work to be concreted and then completed by reinforcing elements which either do not could be part of the prefabricated pieces, either used to assemble the various parts hides.
• this prefabrication requires heavy installations located at a distance from the site, which means that this option is only possible provided that the prefabricated pieces are produced in panels respecting the road gauge (to be able to be transported and then cut on site ), or are precut in the workshop and then transported (provided of course that the pieces thus precut themselves respect the road gauge.
• This option however has the disadvantage of a small number of possible meshes for the prefabricated pieces and of a low choice in the diameters of the rounds used, - it is ultimately quite difficult to manage (supply, assembly, etc.)
• document FR-2,639,390 teaches to position reinforcement components, according to a previously defined distribution diagram which corresponds in particular to the longitudinal distribution of the components or families of components, by memorizing this diagram, in effect killing an electronic reading of the memory and automatically transposing the data on a support to display the distribution of at least one component or family of components.
• This display is done using longitudinal rules provided with hardware markers, for example luminous (diodes) admitting several states.
• hardware markers for example luminous (diodes) admitting several states.
• this solution has the disadvantage of only applying to simple diagrams involving longitudinal components having an imposed initial configuration (in abutment against a cross member) and transverse components which in principle must have fixed transverse positions. .
• this solution does not make it possible to dispense with the obligation of an indirect location when the reinforcement components are installed.
• their assembly is conventionally carried out (see in particular document FR-2,691.996): - by ligating with annealed wire,
• the object of the invention is to overcome the aforementioned drawbacks by means of a method and an installation intended for its implementation, which allows in a simple manner, fast and yet reliable, the preparation and assembly of a concrete reinforcement, in. strict compliance with a design plan, whatever the complexity of this plan (whether it corresponds to a slab, a pre-slab or a vertical panel). Consequently, it aims to alleviate the practical constraints that design offices have to take into account when determining a reinforcement design plan and therefore to allow better optimization of reinforcement taking into account the calculations of strength of materials.
• the assembly is a welding by addition of metal
• the carriage further comprises a degree of freedom in vertical translation and the assembly operation comprises a sub-operation d bringing the assembly tool successively to each assembly point provided by the design plane
• the carriage further comprises a degree of freedom in rotation
• a surveillance field surrounding a specific action area of said tool is made to be monitored by an optical sensor integral with the tool, and the configuration of the carriage is corrected by the robot if this specific action area is at deviation of a crossover zone between reinforcing elements detected in the surveillance field, so as to cancel this deviation
• an optical field of view is chosen for the optical sensor which is on the work surface an area whose dimensions are substantially equal to predetermined tolerances between real assembly points and theoretical points conforming to the design plan, and triggers an alarm when no crossing zone is detected in the surveillance field and the tool is at an assembly point provided by the plan,
• the tracing operation includes a shuttering tracing sub-operation.
• the invention also provides an installation for the preparation and assembly of a flat reinforcement for a concrete product according to a predetermined design plane, comprising a work plane having two reference directions and an assembly tool for assembling the reinforcing elements previously placed on the work surface at a plurality of crossing points, characterized in that it also comprises, for the assembly tool, a robot comprising a memory area intended for contain all the data of the design plan, and a carriage carrying said assembly tool, having at least two degrees of freedom parallel to the reference directions, and adapted to be moved, with said assembly tool, by the robot in accordance with all the data in the memory area for assembly.
• the assembly tool is a device for welding by adding metal
• the carriage further comprises a degree of freedom in vertical translation
• the carriage further comprises a degree of freedom in rotation
• the trolley also carries a vision equipment secured to the tool having a surveillance field surrounding a punctual zone of action of said tool, the robot comprising software making the robot correct the configuration of the trolley if this punctual zone of action is away from a crossing zone between reinforcing elements detected in the surveillance field, so as to cancel this gap,
• the vision equipment has a field of view intercepting on the work plan an area whose dimensions are substantially equal to predetermined tolerances between real assembly points and theoretical points in accordance with the design plan, and is adapted to trigger an alarm when no crossing zone is detected in the surveillance field and the tool is at an assembly point provided by the plan,
• a tracing tool for drawing in real size on the work plan a plan indicating the location and the type provided by the design plan for each element of the frame to be produced, and a carriage carrying said tool plotting, having at least two degrees of freedom parallel to the reference directions, and adapted to be moved, with said plotting tool, by the robot in accordance with all of the data in the memory area for plotting
• the tool for tracing comprises a reserve of ink or paint whose color is chosen as representative of a particular type of reinforcing elements
• the installation comprises, for the tool of tracing, reserves of ink or paint respectively having the colors representative of the various types of reinforcing elements
• the installation also includes a supply of ink or paint for tracing.
• each of the layout and assembly tools is fixed to the cart of the same robot, the layout and assembly tools are attached to different robot carts,
• the robot has a gantry movable longitudinally along its working area, and the carriage is movable on this gantry transverse to this working area,
• the robot has, parallel to its direction of movement, a dimension smaller than its dimension measured transversely to this direction of movement and to the maximum width of the road gauge.
• - Figure 1 is a plan view of a possibility of the installation according to the invention, intended for the preparation and assembly of the frames;
• - Figure 2 shows the plan view of the first work phase, that is to say the tracing of the position of the frames by the gantry on scale 1;
• FIG. 3 shows the plan view of the second work phase, that is to say the placement of the frames according to the tracings made in the previous phase;
• FIG. 4 shows the plan view of the third work phase, that is to say the bonding of the frames by the welding robot gantry;
• FIG. 6A, 6B and 6C show the welding robot in front view, side view and bottom view
• FIG. 7A and 7B show the diagram of the kinematics of the installation of a concrete ring which "rolls";
• FIG. 9 shows the field of the optical sensor with the end of the welding gun. According to the invention, it is therefore possible to trace directly the plane of the reinforcement panel from the established plane by the design office using a CAD system specific for reinforcements (of any suitable known type).
• the information is entered on site using a D.A.O. system.
• the positioning of the reinforcements during the realization of the plan using the computer-aided drafting system (CAD) is advantageously carried out with the help of particular points of the formwork (concreting stops, reservation, locations of the incorporated metal parts ).
• the concordance with the formwork plan can be checked in detail, the only tracing of the reinforcements on scale 1 using a robot designed for this use becomes sufficient to achieve the positioning of the reinforcements in perfect agreement with the plans formwork.
• the tracing robot is for example constituted by a gantry ensuring the tracing of the locations of the reinforcements to be positioned to make the panel.
• This robot is in the form of a gantry crane whose chassis of mechanically welded design ensures both its framework, the support of the transverse guides with its tracing unit and the natural fairing of the mechanical transmissions and on-board equipment. Its width is adapted on a case-by-case basis depending on the width of the panels to be produced.
• the measurement along the longitudinal axis can be ensured either by a smooth large diameter wheel fitted with cleaning devices, located between the two drive wheels and rolling on the reference rail, or by a toothed wheel also located between the two wheels and meshing on a shooting rack located along the track.
• the transverse axis is materialized by two precision guides of length adapted to the width of the panels and between which moves a carriage mounted on precision rollers. On this axis, the measurement is taken directly on the motorization, the drive being without slip.
• the motorizations of the two axes are of robotic type and the transmissions are made by toothed belts which allows the plotting robot to make bias and curved plots with very high precision.
• the materialization of the tracing is done using water-based paint, which has the particularity of being very visible while permanently adhering to the work surface.
• the automation is managed by a central unit integrated into the chassis of the plotting robot. This, on the one hand, stores the orders of the layout of the panels in the format
• HPGL HPGL and, on the other hand, manages all manual and automatic functionality. Data transfer is carried out by means of rigid magnetic cards or by serial link.
• the power supply will be by reel.
• the site foreman who received from the design office a memory card containing the data for tracing the sketch necessary for the implementation of the reinforcements of the panel to be assembled, introduces this card into the reader of the plotting robot.
• the site manager transfers the data to the memory of the plotting robot.
• the plotting robot is then operational.
• the plotting robot is positioned at the start of the process by the site manager using manual controls.
• the plotting robot can be started.
• the reinforcements are arranged by operators according to the traces of the reinforcements produced by the tracing portal.
• the realization of the traces on the scale allows a quick visual control of the shape parameters of the reinforcement that it has just set up.
• the reinforcements when the diameter of the reinforcements specified by the plan and its nomenclature allows, the reinforcements come from a decoiler-stiffener-shaping machine installed near the work trays, using armatures supplied in reels.
• the characteristics of the reinforcements (length, shapes %) come directly from the nomenclature established by the CAD system. For the characteristics of reinforcements that do not allow it, the reinforcements will be cut and shaped in traditional workshops.
• the characteristics of the reinforcements can come directly from the computerized nomenclature of the plan established by the D.A.O. system. without new entry operation.
• the frames are bonded by adding metal.
• the welding gun is, as for tracing, guided by the information coming from the computer system having been used to draw the execution plan for the reinforcements.
• a digital vision system or, more generally, an optical sensor allowing shape recognition, makes it possible to correct the trajectory of the welding gun in order to adapt the position of this welding gun relative to the intersection to be bonded (distance torch / point , angle of approach, point of impact of the arc).
• To the movement of the carriage in two horizontal directions is preferably added a rotation about a horizontal axis. There is also a vertical movement near each assembly to be produced.
• a control unit manages the welding system and the optical sensor. From the analysis of the diameters of the reinforcements constituting the intersection and from the location of the precise position of these reinforcements, are deduced the very optimal welding parameters (positioning angle of the gun, welding current intensity, wire feed speed welding flux-cored wire, etc.).
• This capacity for self-adaptation of the welding system enables quality bonding of the concrete rods, whatever the diameter of the reinforcements, despite the shape parameters of the concrete rods (height, spacing, length, inclination of the locks or of the indentations) which cause a natural displacement of this concrete ring compared to the theoretical positioning of the plan.
• the adjustment of the digital vision system or of the optical sensor is carried out so that the bonding of the intersections of the reinforcements is carried out only within the tolerances defined by the regulations for the calculation of reinforced concrete, or even within the tighter tolerances required for a structure. particular.
• a work station, intended for the assembly of concrete reinforcing bars, is shown in FIG. 1.
• the tracing gantry for the reinforcements 10 is positioned at the start of its raceway 20 which will allow it to cover the work platform 30
• the site manager introduces the computer diskette 11 into a reader connected to the central unit 12 (FIG. 5) integrated into the frame of the gantry.
• the computer diskette 11 contains the tracing data of the reinforcement plan established using the software of D.A.O. After transferring the data from the diskette to a memory in the central unit, the site manager removes the diskette.
• the tracing portal is operational.
• the tracing gantry 10 at the end of its raceway 20, has materialized the future positioning of the reinforcements on the work plate 30.
• the plate 30 has been moved to the area where the reinforcements will be arranged according to the traces produced by the gantry 10.
• the work trays move along the raceway 21 thanks to the roller skates on which they are fixed.
• the reinforcements when their characteristics allow it, according to an example of a particular organization of the position for implementing the reinforcements of the invention, given only as an indication, are straightened, cut, shaped using the straightening-cutting machine.
• -moulder 40 from reels of reinforcing wire 41.
• the characteristics ques shaping these frames can come from the information contained on the disk 11 and then loaded on a central unit 42 controlling the rectifier-cutter-moulder in a new entry is necessary.
• the gantry after loading the data, traces another reinforcement element on the plate 31.
• the plate 30 has been transferred into the zone of evolution of the welding gantry 50 which can move along the raceway 23.
• the possibility of being able to move the plate 30 from the zone for fitting the armatures towards the evolution area of the gantry 50 and vice-versa gives the possibility of assembling sheets with a number of beds greater than 2. For example, after assembling the first two beds, the tray is brought back to the laying area for the establishment of a third bed which will be assembled to the second bed after movement in the area of evolution of the gantry 50.
• the computer diskette 11 supporting the information coming from the D.A.O. system. , is inserted into the floppy drive 51 of the central unit 52 (FIG. 6).
• the information transmitted makes it possible to guide the mobile assembly 53 comprising an arm 54 articulated along 4 axes supporting a welding gun 55 and an optical sensor 56.
• the trajectory of the mobile assembly 53 is controlled by the information coming from the CAD system following, in a preferential manner, the trace of the upper reinforcements.
• the optical sensor 56 analyzes the position of the upper reinforcement 71 and the position of the lower reinforcement 72, then compares their respective respective positions (marked by the centers) 73 with their theoretical positions 74 given by the information contained in the computer file generated by the CAD / CAM system.
• the optical sensor 56 also compares these measured diameters with the theoretical diameters of these reinforcements given by the information contained in the computer file of the plan of the reinforcement element created by the D.A.O. system. and transferred to the central processing unit 52 of the welding robot.
• the programming of the system is done in such a way that the welding process can only be carried out if the diameters comply with the plan and the positioning of the reinforcements constituting the intersection is within the defined execution tolerances.
• the optical sensor 56 acquires the profile of the intersection.
• the analysis makes it possible to deduce the optimal welding parameters, then to adapt the trajectory of the welding gun for positioning optimal of this welding gun compared to the intersection to be glued (torch / point distance, approach angle, point of impact of the arc).
• the invention provides a great improvement to the existing technique by providing a device for the production of reinforcing elements for reinforced concrete, allowing the assembly with great flexibility (and therefore, consequently, the design of plans likewise with great flexibility), with the possibility of manufacturing either in the factory or on site under the same quality conditions as using computerized self-checking.
• the vision system is more generally an optical sensor: it is for example the optical laser triangulation sensor proposed by the Canadian company SERVOROBOT under the reference SPOT,
• the gantries are for example of the type used in another application, namely ROBOTRACE from the French company
• the invention is not limited to the sole production of flat panels, but that it also applies to the manufacture, under the same conditions, of curved panels or other shapes with the use of conventional negatives or folding systems. Similarly, productivity concerns can lead to mounting several tools on a gantry.

Landscapes

• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Automatic Assembly (AREA)
• Reinforcement Elements For Buildings (AREA)
• Butt Welding And Welding Of Specific Article (AREA)
• Rod-Shaped Construction Members (AREA)
• Conveying And Assembling Of Building Elements In Situ (AREA)
• Panels For Use In Building Construction (AREA)
• Sewage (AREA)
• Manipulator (AREA)

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• 1995
  • 1995-03-03 FR FR9502500A patent/FR2731247B1/fr not_active Expired - Fee Related
• 1996
  • 1996-02-29 ES ES96905890T patent/ES2138325T3/es not_active Expired - Lifetime
  • 1996-02-29 AU AU49470/96A patent/AU4947096A/en not_active Abandoned
  • 1996-02-29 US US08/894,814 patent/US6029880A/en not_active Expired - Fee Related
  • 1996-02-29 DE DE69604055T patent/DE69604055T2/de not_active Expired - Fee Related
  • 1996-02-29 WO PCT/FR1996/000318 patent/WO1996027462A1/fr active IP Right Grant
  • 1996-02-29 AT AT96905890T patent/ATE183952T1/de not_active IP Right Cessation
  • 1996-02-29 CA CA002212555A patent/CA2212555A1/fr not_active Abandoned
  • 1996-02-29 EP EP96905890A patent/EP0813457B1/de not_active Expired - Lifetime
  • 1996-02-29 DK DK96905890T patent/DK0813457T3/da active
• 1999
  • 1999-11-25 GR GR990403042T patent/GR3031949T3/el unknown

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