WO2002070169A1

WO2002070169A1 - Cage making apparatus

Info

Publication number: WO2002070169A1
Application number: PCT/GB2002/000922
Authority: WO
Inventors: Kamal Neckoula
Original assignee: NGR Ltd
Current assignee: NGR Ltd
Priority date: 2001-03-07
Filing date: 2002-03-06
Publication date: 2002-09-12
Anticipated expiration: 2003-09-07

Abstract

An apparatus for making a cage comprises a first carrier means (121) for holding elongate components (130) of a cage, a second carrier means (122) for carrying a peripheral component (70) of the cage, and a third carrier means (140) for dispensing a wrapping component (144) of the cage. A motor (38) is associated with at least one of the carrier means for moving the peripheral component (70) and elongate components (130) attached thereto linearly and rotationally relative to the third carrier means, whereby the wrapping component (144) is wrapped onto the elongate components (130) along their lengths.

Description

Cage Making Apparatus

This invention relates to cage making apparatus. In particular, it relates to apparatus for making elongate steel cages for reinforced concrete piles, foundations and so forth.

Steel cages are most typically assembled from steel bands, formers and rings welded to longitudinal bars. Traditionally, assembly of such cages has been a manual fabrication operation. This is a laborious and time-consuming operation that requires extensive preparation, but is still in widespread use. This is in part because there is a requirement that cages be made on-site to a wide range of specifications and configurations, meaning that any system for making cages must be both flexible and transportable if it is to receive widespread acceptance.

There is, therefore, a demand for apparatus that can automate production of cages with a view to reducing time and labour required, while maintaining the flexibility and range of application of manual systems. An aim of this invention is to provide such apparatus.

Accordingly, from a first aspect, this invention provides an apparatus for making a cage comprising a first carrier means for carrying elongate components of the cage; a second carrier means for holding a peripheral component of a cage; a third carrier means for dispensing a wrapping component of the cage; and transport means associated with at least one of the first carrier means and the second carrier means for causing relative rotational and linear movement between the third carrier means and the peripheral and elongate components of the cage, whereby the wrapping component is wrapped onto the elongate components.

This apparatus can enable construction of a cage with a peripheral component, longitudinal components and a wrapping component in an automated process. The first, second and third carrier means may all be provided in association with a chassis. For example, the first carrier means may be movable linearly with respect to the chassis and the second carrier means may be fixed against linear movement with respect to the chassis. The third carrier means may also be movable linearly with respect to the chassis.

In preferred embodiments of the invention, the second carrier means includes a module having a frame within which the peripheral component can be mounted for rotation, most advantageously, under power e.g. by an electric or hydraulic motor.

In typical applications, the peripheral component is a ring, for example, of metal, and typically of robust construction. The ring may have a circular, polygonal or other peripheral shape.

The first carrier means may also include a module within which a jig is carried for rotation about an axis generally parallel with the length of the elongate components, the jig being suitable for supporting elongate components of the cage. Most advantageously, the jig can be rotated under power e.g. by an electric or hydraulic motor.

The jig may include a plurality of radial spokes that define between them spaces for receiving the elongate components. The jig serves as a support element for the elongate components and causes them to rotate with the peripheral component during the winding process. The spaces between the spokes extend radially, allowing the radial positions of the elongate components to be adjusted. Therefore, whereas machines that use jigs of fixed diameters can only be used to manufacture cages having those specific diameters, the machine of the present invention be used to manufacture cages of many different diameters, without having to conform to the diameters of available jigs.

The third carrier means may include a drum upon which the wrapping component is wound. Such a drum will most usually be carried for rotation about an axis that is approximately parallel to the length of the elongate components. Most usually, the wrapping component is wire. The third carrier means may be fixed against linear movement with respect to the first carrier means. The apparatus may further comprise an additional carrier means for supporting the elongate components of the cage. The additional carrier means may be movable linearly with respect to the second carrier means. The additional carrier means may include a jig carried for rotation about an axis generally parallel with the length of the elongate components, the jig being suitable for supporting elongate components of the cage. Alternatively, the additional carrier means may include a fixed support, for example having a U-shape, within which the elongate components can rotate.

The jig of the additional carrier means includes a plurality of radial spokes that define between them spaces for receiving the elongate components, thereby providing the advantages as discussed above in relation to the first carrier means.

During construction, the elongate components of the cage may be secured around a periphery of the peripheral component. Typically, the elongate components are movable in a circular locus about an axis that passes through the peripheral component (for example, though its centroid, parallel to the length of the elongate components).

Embodiments of the invention will now be described in detail, by way of example, and with reference to the accompanying drawings, in which:

Figure 1 is a general side view of a cage making apparatus being a first embodiment of the invention, showing a completed square-section cage;

Figure 2 shows the embodiment of Figure 1, in partial cross-section, in a condition prior to starting to make a cage;

Figure 3 is a view equivalent to Figure 2 with a round-section cage in a part-completed condition;

Figure 4 is a view equivalent to Figure 1 with the round-section cage of Figure 3 in a completed condition;

Figure 5 is a plan view of a first or a second module being a component of the embodiment of Figure 1; Figure 6 is a plan view of a third module being a component of the embodiment of Figure l;

Figure 7 shows a side view of cradles for the modules of Figures 5 and 6 mounted on chassis beams of the embodiment of Figure 1;

Figure 8 is an plan view of a module of the embodiment of Figure 1 ;

Figure 9 shows an end view of the cradle of Figure 7;

Figure 10 is an enlarged detailed view of a suspension assembly of a module, such as that shown in Figure 7;

Figure 11 is an end view of a drum frame of the second module of the embodiment of Figure 1;

Figure 12 is an end view of a drum frame of the second module of the embodiment of Figure 1;

Figure 13 is an end view of a drum frame of the second module of the embodiment of Figure 1;

Figure 14 is a more detailed view of a drum suspension assembly of the first module such as illustrated in Figures 11 to 13;

Figure 15 is a side view of a drum of a module such as illustrated in Figures 11 to 13;

Figures 16 and 17 are views of a roller unit of the embodiment of Figure 1 in, respectively, a lowered and a raised condition;

Figure 18 is an end view of a wire carrier assembly being a component of the apparatus of

Figure 1;

Figure 19 is a general side view of a cage making apparatus being a second embodiment of the invention, in a condition prior to starting to make a cage;

Figures 20, 21 and 22 are general side views equivalent to Figure 19, showing a round-section cage in various stages of completion;

Figures 23 and 24 are end and side views of a first module of the embodiment of Figure 19;

and Figures 25 and 26 are end and side views of a first module of a third embodiment of the invention.

With reference to Figures 1 to 18 of the drawings, a first apparatus embodying the invention is constructed on a chassis frame comprising a pair of steel beams 10 of I-shaped cross-section that extend the length of the apparatus, parallel to a long axis that will be referred to as "the machine axis". The beams 10 are parallel and maintained spaced-apart by spacers 12. The beams 10 are selected to confer the apparatus with a highly rigid construction, and additional cross-bracing between the beams is provided to this end. Each beam 10 has an upper and lower flange, each being generally horizontal, and being interconnected by a vertical web. On a lower surface of the upper flange of each beam 10 there is fixed a downwardly directed rack gear 14.

A plurality of functional components are carried on the frame. These include modules, and roller units.

This embodiment has three modules of different types, referred to as the first, second and third modules, and indicated respectively, at 121, 122 and 123. The various types of modules have a similar basic construction. Each module comprises a support frame 20 formed of steel section.

In the case of the first and third modules, at spaced lower portions of each support frame 20 is a suspension assembly 22. With reference to Figure 10, each suspension assembly 22 includes a plurality of rollers 30. The rollers 30 are free to rotate about an axis 32 that is disposed (when the module is in use) generally transversely of the machine axis. The rollers 30 are supported upon a flat, upwardly-directed flange of the upper flange of the beams 10 to carry the support frame 20 such that it may be moved along the length of the beams 10. The suspension assembly also includes a toothed pinion 34 that is carried on a drive shaft 36 for rotation about an axis parallel to that of the rollers 30. A motor 38 is provided to drive the shaft 36 and thereby the pinion 34. The drive shaft 36 interconnects pinions 34 of suspension units on opposite sides of the frame, thereby ensuring that the pinions rotate together. The motor may be electric, hydraulic or otherwise powered according to preference and the availability of power where the apparatus is to be used. The pinion 34 is, in use, in engagement with the rack gear 14 of the associated beam 10, such that rotation of the pinion 34 causes the suspension assembly 22, and the support frame 20 attached to it, to be driven along the beams 10, parallel to the machine axis.

Each module further includes a drum frame 40 that, in use, projects upwardly from the support frame 20. In this embodiment, the first and second modules 121 , 122 have a drum frame formed as a box 2050mm square and 1000mm deep (measured along the length of the chassis).

Within the drum frame is a total of eight drum suspension units 42. The drum suspension units 42 are disposed in two planes spaced apart longitudinally of the module in corner regions of the drum frame 40.

Each drum suspension unit 42 (shown most clearly in Figure 14) includes a wheel 46 carried on a shaft for rotation about an axis generally parallel to the machine axis. Each wheel has an outer surface formed with gear teeth. The shaft passes through the wheel 46 of each of two of the suspension units to ensure that the wheels rotate together. Each wheel 46 is carried on a bearing that is secured within a bearing block 48, which is carried in a carrier 50. The bearing block 48 can slide within the carrier under the control of a compression spring and an adjusting bolt whereby the bearing block can be moved in order to adjust the position of the wheel 46 from the centre of the drum frame 40.

A drum 50 is carried by the drum suspension units 42 within the drum frame 40. The drum

50 has an approximately cylindrical profile, being formed from rolled steel plate, that extends with its axis parallel to the machine axis. Two bands 52 encircle the drum 50, the bands forming a toothed ring gear that is in mesh with the wheels 46 of the drum suspension units 42. In this way, the drum 50 can be rotated by rotation of the shaft upon which the wheels 46 are carried, this rotation being under the control of a motor, that is electrically, hydraulically or otherwise powered.

In each case, the drum 50 is 1750mm in diameter. In the case of the first and second modules 121, 122, the drum is 1500mm in length while in the third module, it is 1000mm in length. The length of the drum 50 is such that axial end portions of it project axially beyond the drum frame 40. A plurality of radial, regularly spaced apertures 62 are formed through the drum 50 in one of these projecting axial end potions.

A cage that can be constructed by apparatus of this embodiment includes a support ring, constructed of steel to have substantial strength. The support ring forms a peripheral component of the cage, normally disposed close to one or both ends of the cage and also sometimes at one or more intermediate positions. A plurality of longitudinal bars of the cage are attached to the outer circumference of the support ring by welding, tying or otherwise. The cage is completed with helical wire wrapped around the longitudinal bars. It should be noted that the support ring need not have a circular cross-section. It may have one of a wide range of shapes, including circular, oval, or polygonal. This apparatus makes use of the ring in the process of constructing the cage.

The ring 70 is secured within the drum 50 of the second module 122, where it is supported with its centre located substantially at the centre of rotation of the drum 50. Adjustable clamps 72 are provided within the drum 50 to secure rings 70 of various shapes and sizes.

In the first module 121, ajig 80 is located within the drum frame 40 in place of the ring of the second module 122. As is the case with the second module 122, the jig can be rotated by a motor. The jig 80 carries many straight tubes 84 within a supporting framework, the tubes being arranged to extend parallel to the machine axis. The tubes 84 are arranged to be spaced around a plurality of generally circular loci at different radii from the centre of rotation of the jig 80. The tubes 82 are of diameter to allow sliding passage of longitudinal bars used in the construction of the cage. The second module 122, at least while the apparatus is in use, is fixed against movement in the direction of the machine axis. The third module 123 carries ajig 86 similar to, but of lesser axial extent than, the jig 82 of the first module 121. The jig 86 is free to rotate within the frame, and the third module 123 is free to travel along the beams 10.

Depending upon the size and configuration of the cage to be built, the apparatus will normally comprise the first and second modules 121, 122. The third module 123 is optional. Where the cage is particularly long, several modules identical to the third module 123 may be provided to support the elongate elements 130 along their lengths.

In addition to the modules, the apparatus includes one or more roller units 100 carried between the beams 10, spaced apart along their length. Each roller unit 100 comprises a pair of cylindrical, elongate rollers 102 carried for rotation about parallel roller axes on a roller frame 104. The roller frame 104 is carried on a lifting frame 106, that is constructed generally as a four-bar linkage of parallelogram configuration. Associated with the lifting frame 106 is a hydraulic ram 110, configured such that extension of the ram 110 causes the lifting frame 106 to raise the roller frame 104 and the rollers attached to it from a lowered to a raised condition.

Each of the roller units 100 is disposed between the beams 10, such that the rollers 102 extend generally horizontally and parallel to the beams 10, and are spaced equally between them. The lifting frame is configured such that the rollers 102 remain generally horizontal as they are lifted under the action of the ram 110. While the roller frame is in the lowered condition, modules 40 carried on the beams 10 can travel along the beams, passing over the roller unit 100.

The apparatus further comprises a wire carrier assembly 140. The wrapping wire assembly is provided adjacent to the first module 121, alongside the beams 10.

The wire carrier assembly includes a wire drum 142 upon which is wound a length of wrapping wire 144. The wire drum 142 is carried on a stand 146 such that it can rotate about an axis that is parallel with the machine axis. Wire uncoiling from the drum 142 is directed to pass through a wire guide 148. The wire guide 148 ensures that the wire at all times follows a predetermined path extending transversely of the machine axis to the first module 121, and that the wire is under controlled tension.

Several supporting platforms 90 are provided between the beams 10 adjacent to the third module 123. The platforms 90 carry rollers, each being free to rotate about an axis transverse of the machine axis at approximately the centre height of the modules.

In use, the first step is to select a support ring 70 suitable for construction of a required cage, and to mount the ring 70 within the second module 122. Sufficient longitudinal bars 130 for the cage are then loaded onto the platforms 90 to extend in general alignment with the machine axis. The first module 121 is then traversed along the beams 10 until it is adjacent to the second module 122, as shown in Figure 2.

One bar 130 at a time is then passed through an appropriate tube 84 of the jig 82 of the third module (or modules), and then through a tube of the jig of the first module 121. An end portion of the bar 130 is then secured (for example, welded, tied or bolted) to an appropriate position on the ring 70. The drums of the modules are then rotated simultaneously, by an incremental amount, such that this securing process can be repeated for the next bar, until all have been secured.

The assembly thereby produced, shown in Figure 3 , comprises a skeleton cage of a ring 70 and longitudinal bars 130 that will become part of the finished product, supported in temporary jigs spaced along the length of the longitudinal bars 130.

An end of the wrapping wire 144 is then secured to one of the longitudinal bars 130, close to the ring 70. Motors of the first and second modules 121, 122 are started to cause their drums to rotate synchronously. At the same time, the motor of the first module 121 is started to cause the module to travel along the beams 10 away from the second module 122. The wire carrier 140 travels with the first module 121, causing relative movement both in translation and in rotation between the skeleton cage and the wire carrier. This causes wrapping wire 144 to be withdrawn from the wire drum 142 through the wire guide

148 and wrapped in a helical pattern around the longitudinal rods 130. The third module 123 follows the first module 121, both in rotation and in motion along the beams 10. In a simple case, the above-described process is continued until the cage is completed, whereupon the wire 144 is secured and cut, and the finished cage, comprising ring, longitudinal rods and wrapping wire is removed from the machine. In other cases, variations on the basic method may be employed.

First, some cages are constructed with additional support rings, which serve as strengthening hoops. If these are required, the wrapping process may be temporarily suspended while each hoop is fitted manually, for example, by welding the loops to the longitudinal rods.

Second, the pitch of the helix formed by the wire 144 can be selected by varying the rate of rotation of the elongate elements with respect to their longitudinal movement. If need be, this can be varied along the length of the cage.

It may also be that the cage is so long as to require support along its length. This can be achieved by raising one or more roller unit 100 in order that its rollers 102 bear against and support the rotating, part-formed cage.

An example of an apparatus according to a second embodiment of the invention is shown in Figures 19 to 24 of the drawings. This apparatus is similar in most respects to the first embodiment shown in Figures 1 to 18 and, except as indicated below, the description of the first embodiment applies also to the second embodiment. Where appropriate, similar reference numerals have been used to identify similar parts.

The second module 222 is substantially identical to the second module 122 of the first embodiment described above. However, the apparatus uses modified versions of the first module 221 and the third module 223.

The modified version of the first module 221 is shown in figures 23 and 24 (this version being slightly different in construction to that shown in Figs. 19 to 22, but similar in principle). The module includes ajig 280 that is mounted for rotation within a frame 240 and is driven by a motor (not shown). The jig 280 includes a large number of spokes 282 that extend radially from an inner cylindrical tube 284 to a circular supporting framework 286. The spokes 282 are arranged to be spaced equi-angularly from one another and provide between them a plurality of spaces to allow sliding passage of longitudinal bars used in the construction of the cage. Rollers 288 attached to the framework 286 engage a roller track in the frame 240, allowing the jig to rotate.

The spokes 282 serve to support and separate the longitudinal bars of the cage and allow them to rotate with the cage during the winding process. They also allow radial displacement of the longitudinal bars, for example to permit the insertion into the semi- assembled cage of one of more additional support rings.

The first module 221 is mounted on a suspension assembly 22 having rollers 30 that engage the I-shaped beams 10 and is arranged for movement in the direction of the machine axis along the chassis frame, driven by a motor (not shown).

The wire carrier assembly 140 (which for clarity is omitted from Figs. 19 to 24) is either connected to or operably associated with the first module 221 and, during use, moves along the machine axis with that module. The wire carrier 140 is arranged to feed the wrapping wire onto the skeleton cage at a point between the first and second modules 221 222, for example approximately one metre from where the longitudinal bars pass through the jig 280. This allows additional support rings to be inserted into the cage where required.

The modified version of the third module 223, which is shown in Figures 25 and 26 and is similar in many respects to the modified first module 221, includes ajig 290 with a plurality radial spokes 292. The jig 290 is mounted for rotation within a frame 260 that extends around approximately three quarters of the circumference of the jig 290, leaving a mouth 262 through which the longitudinal bars may be inserted into the spaces between the spokes 292. Rollers 294 attached to the spokes of the jig 290 engage a roller track in the frame 260, allowing the jig to rotate freely. A table 264 is provided adjacent to the lower jaw of the mouth 262 to support the longitudinal bars before they are introduced into the jig 290. A U-shaped guide rail 266 extends around the bottom half of the frame 260 to limit outward movement of the longitudinal bars during rotation of the jig and prevent them from contacting the frame. The third module 223 includes a suspension unit 22 having rollers 30 that engage the I-shaped beams 10 and is arranged for movement in the direction of the machine axis along the chassis frame.

Operation of the machine will be described with reference to Figures 19 to 22, which show successive steps of a process for manufacturing a reinforcing cage. Figure 19 shows how the machine is set up prior to constructing a reinforcing cage. The first and second modules 221 ,222 are positioned close to one another at one end of the machine chassis and, if required, one or more support modules 223 are spaced along the remaining part of the chassis. A set of longitudinal reinforcing bars 130 is placed on tables 270 adjacent the third modules 223 and a peripheral support ring is mounted in the second module 222.

As shown in Figure 20, the longitudinal bars 130 are introduced at spaced intervals into the support modules 223 and inserted axially through the first and second modules 221,222 and fixed to the peripheral support ring 70, to form a skeleton cage. When all the bars have been fixed, one end of the wrapping wire 144 is fixed to the skeleton cage adjacent the peripheral ring and the rotary drive motors of the first and second modules 221,222 are started, causing the skeleton cage to rotate. At the same time, the axial drive motor of the first module 221 is started, transporting the first module and the winding apparatus 140 away from the second module 222, thereby wrapping the wire 144 helically onto the skeleton cage, as shown in Figure 21. The completed part of the cage is supported by rollers 100, which are lifted to engage the cage after the first module 221 has passed. When the first module 221 encounters one of the third modules 223, it simply pushes that module axially along the machine chassis.

Periodically, for example at intervals of about two metres, the wrapping process may be paused to allow the insertion of a support ring into the cage, between winding apparatus 140 and the point where the longitudinal bars 130 pass through the jig of the first module 221.

After the winding process has been completed and the first module 221 has travelled beyond the end of the cage, the peripheral support ring 70 is disengaged from the second module 222 and the cage is withdrawn from that module (Figure 22). Various additional modifications of the apparatus are of course possible, some of which will now be described.

The jig of the first module 221 may include a number of internal divider rings of different diameters, which are attached to the spokes 282 to limit radial movement of the longitudinal bars 130.

The mouth 262 of the third module 223 may be made smaller, or may be omitted altogether. In this latter case, the longitudinal bars 130 would have to be fed axially through the module.

The third modules 223 may not be required, particularly for short reinforcing cages, and may be omitted or replaced by simple U-shaped frames that support the free ends of the longitudinal bars and allow them to rotate around one another during the winding process. These U-shaped frames may be mounted for axial movement along the chassis or alternatively simple removable support stands may be provided.

Claims

1. Apparatus for making a cage comprising:

a first carrier means for carrying elongate components of the cage;

a second carrier means for holding a peripheral component of a cage;

a third carrier means for dispensing a wrapping component of the cage; and

transport means associated with at least one of the carrier means for causing relative rotational and linear movement between the third carrier means and the peripheral and elongate components of the cage, whereby the wrapping component is wrapped onto the elongate components.

2. Apparatus according to claim 1 in which the first, second and third carrier means are all provided in association with a chassis.

3. Apparatus according to claim 2 in which the first carrier means is movable linearly with respect to the chassis.

4. Apparatus according to claim 2 or claim 3 in which the second carrier means is fixed against linear movement with respect to the chassis.

5. Apparatus according to any one of claims 2 to 4 in which the third carrier means is movable linearly with respect to the chassis.

6. Apparatus according to any preceding claim in which the second carrier means includes a module having a frame within which the peripheral component can be mounted for rotation.

7. Apparatus according to claim 6 in which the peripheral component is mounted for rotation under power by an electric or hydraulic motor.

8. Apparatus according to any preceding claim suitable for use where the peripheral component is a ring.

9. Apparatus according to claim 8 in which the ring is of metal.

10. Apparatus according to claim 8 or claim 9 in which the ring has a circular, polygonal or other peripheral shape.

11. Apparatus according to any preceding claim in which the first carrier means includes a module within which ajig is carried for rotation about an axis generally parallel with the length of the elongate components.

12. Apparatus according to claim 11 in which the j ig is suitable for supporting elongate components of the cage.

13. Apparatus according to claim 11 or claim 12 in which the j ig can be rotated under power.

14. Apparatus according to any one of claims 11 to 13 in which the jig includes a plurality of radial spokes that define between them spaces for receiving the elongate components.

15. Apparatus according to any preceding claim in which the third carrier means includes a drum upon which the wrapping component is wound.

16. Apparatus according to any preceding claim in which the third carrier means is fixed against linear movement with respect to the first carrier means.

17. Apparatus according to any preceding claim suitable for use where the wrapping component is wire.

18. Apparatus according to any preceding claim further comprising an additional carrier means for supporting the elongate components of the cage.

19. Apparatus according to claim 18 in which the additional carrier means is movable linearly with respect to the second carrier means.

20. Apparatus according to claim 17 or claim 18 in which the additional carrier means includes ajig carried for rotation about an axis generally parallel with the length of the elongate components, the jig being suitable for supporting longitudinal components of the cage.

21. Apparatus according to claim 20 in which the jig of the additional carrier means includes a plurality of radial spokes that define between them spaces for receiving the elongate components.

22. Apparatus according to any preceding claim in which, in use, the elongate components of the cage are disposed around a periphery of the peripheral component.

23. Apparatus according to claim 22 in which the elongate components are movable in a circular locus about an axis that passes through the peripheral component.