[0001] The present invention relates to a method and an apparatus for forming packs of stirrups
and to the pack of stirrups thus formed.
[0002] It is known that the reinforcement frame of reinforced concrete pillars and beams
is commonly formed by using metal frames constituted by longitudinal iron rods connected
by suitably spaced transverse stirrups. The stirrups usually form a closed path, for
example a quadrilateral one, with overlapping ends. The longitudinal rods are inserted
in the profile formed by the stirrups and are fixed, for example at the comers of
said profile.
[0003] The stirrups are formed by appropriately provided stirrup bending machines according
to the required profile. If the stirrups are not meant for immediate use at the production
site, they must be grouped in order to be able to store them tidily. This operation
is currently performed manually by assigned operators, with obvious discomfort and
fatigue.
[0004] In particular, one common operating method entails allowing the stirrups that exit
from the stirrup bending machine to drop to the ground, where they gradually accumulate.
The operator then picks up the stirrups and places them in a tidy pack to be bound
by way of suitable bindings or the like. The stirrups that pile up on the ground can
easily become entangled, so the operator also has to pick them up from the ground
and disengage them from each other before tidying them up, which leads to an increase
of the work required. Moreover, in the meantime the stirrup bending machine must be
stopped, for obvious reasons, and therefore its productivity is penalized by this
operation.
[0005] In a different operating method, the operator picks up the stirrups directly from
the stirrup bending machine without allowing them to fall and then arranges them tidily,
one after the other, until they form the intended pack. This solution is rational
in itself, but it is not devoid of dangers, since the operator has to work close to
the stirrup bending machine, and also requires constant involvement of the operator.
[0006] The aim of the present invention is to solve the cited problem, by providing a method
that allows to produce automatically packs of stirrups for reinforced concrete.
[0007] Within this aim, an object of the present invention is to provide an apparatus that
allows to perform said method for forming packs of stirrups by way of a structure
that is simple in concept, safely reliable in operation, and versatile in use.
[0008] Another object of the present invention is to provide a pack of stirrups that has
innovative characteristics as regards ease and versatility of use and formation.
[0009] This aim and these objects are achieved, according to the invention, by the present
method for forming packs of stirrups, characterized in that it comprises the steps
of:
(a). arranging or picking up at least one first stirrup at a front input region of
an apparatus for forming packs of stirrups;
(b). picking up said first stirrup from said front input region by way of grip and
welding means that can move along a longitudinal direction with respect to said input
region;
(c). producing the alternating movement of said grip and welding means (5) into a
forward position in order to draw said first stirrup into the same forward position;
(d). fixing at least one longitudinal auxiliary rod externally to said first stirrup,
which is retained by said grip and welding means;
(e). arranging adjacent to said first stirrup drawn into said forward position a series
of additional stirrups, picked up in succession by said grip and welding means at
said input region, so as to form a pack of stirrups;
(f). fixing said longitudinal auxiliary rod externally to at least one last stirrup
of said pack;
(g). cutting said auxiliary rod ahead of said pack thus formed.
[0010] The features of the invention will become better apparent from the detailed description
of a preferred embodiment of the apparatus for forming packs of stirrups, illustrated
by way of non-limitative example in the accompanying drawings, wherein:
Figure 1 is a perspective view of a pack of stirrups formed according to the method
of the invention;
Figures 2, 3, 4, 5, 6, 7, 8 and 9 are side views of the apparatus for forming packs
of stirrups in successive steps of operation;
Figures 10 and 11 are respective perspective views of variously shaped packs of stirrups.
[0011] With reference to the figures, the reference numeral 1 generally designates a working
head of the apparatus for forming packs 10 of stirrups 12 for reinforced concrete
according to the present invention. The apparatus according to the invention duplicates,
in its general features, the structure disclosed in co-pending Italian patent application
B02002A000438, by the same Applicant, to which reference is made for a more complete
general description. Patent application no. B02002A000438 relates to an apparatus
for forming metal cages for reinforced concrete, and therefore the present invention
relates to a different application of said structure.
[0012] The apparatus is adapted to be associated with a conventional stirrup bending machine
2; it should be noted that the stirrup bending machine 2 has a working surface that
is arranged vertically for the sake of convenience.
[0013] The apparatus has a chassis, not shown, which is provided with the working elements
and is arranged in front of the stirrup bending machine 2. A longitudinally elongated
platform 3 protrudes from the chassis and forms a horizontal working surface. The
packs 10 of stirrups are meant to form on the working surface of the platform 3 and
are obtained, as specified hereinafter, by joining one or more longitudinal auxiliary
rods 11 externally to a tidy series of said stirrups 12. The auxiliary rods 11 unwind
from corresponding spools, not shown, which are arranged preferably with a vertical
axis at the sides of the platform 3.
[0014] The chassis of the apparatus supports, in a suitably adjustable position, at least
one working head 1, which is adapted to pick up the stirrups 12, form the pack 10
and weld a respective auxiliary rod 11 to the stirrups 12. In the case shown in Figure
1, the stirrups 12 form a substantially rectangular profile and are mutually connected
by way of three auxiliary rods 11, which are arranged respectively on the lateral
portions and on the lower portion of the stirrups 12, and therefore three working
heads are required.
[0015] Each working head 1 is provided with means 5 for gripping and welding the auxiliary
rod 11 and the stirrups 12 which form the pack 10 of stirrups.
[0016] More specifically, said gripping and welding means 5 provide a grip element 51, which
is constituted by a beak 52 that is directed toward the stirrup bending machine 2
and is rigidly coupled to the stem 53 of a linear actuator 54. The actuator 54 is
fixed to a bracket 55, which is rigidly coupled to a stem 56 that is guided so that
it can slide, in contrast with elastic means 57, through a sliding block 58, which
in turn is rigidly coupled to the stem 60 of a second linear actuator 61, along an
axis that is parallel to the axis of the first actuator 54. The second actuator 61
is supported by a brace 63, which is provided with a pair of stems 64 for guiding
the sliding block 58.
[0017] The bracket 55 is provided with a housing 65 for protecting the beak 52. The bracket
55 is further provided with a protruding roller 59, adapted to act as an abutment
on the front surface of the stirrup bending machine 2.
[0018] The brace 63 is fixed to the end of a pair of horizontal guiding shafts 66, which
pass slidingly through a body 67. At the opposite end, the shafts 66 are fixed, by
means of a plate 68, to the stem 69 of a double-stroke grip actuator 70.
[0019] The body 67 is fixed to a box-like enclosure 74, which acts as a support for a transformer
element 75. A rack 76 is rigidly coupled to the enclosure 74 in a downward region
and is adapted to couple to a corresponding gear 73, which is turned by suitable motor
elements.
[0020] The welding means 8 are supported in a cantilevered fashion in front of the enclosure
74 and are constituted by movable welding units 81, which cooperate with fixed welding
units 82, for example of the resistance welding type, which are open in a forward
direction. The movable welding units 81 are supported by an arm 83, which is suitable
to be actuated by a linear actuator 84. The fixed welding units 82 are mounted on
a body 85, which is supported elastically on stems 86 in contrast with elastic means
87.
[0021] The method for producing packs of stirrups for reinforced concrete by way of the
described apparatus mainly entails picking up automatically or manually the stirrups
12 on the stirrup bending machine 2, which for this purpose is arranged, so that its
working surface is preferably vertical, in front of the apparatus according to the
invention, at an input region E thereof.
[0022] The apparatus grips the stirrups 12 to be picked up by means of the grip elements
51 of the working heads 1 before the step for cutting the stirrups 12 from the material
in bar or coil form from which they are obtained by bending. For this purpose there
is an intermediate stop in the working cycle of the stirrup bending machine 2 in order
to allow the grip elements 51 to grip the stirrups 12 in a point that is certain.
[0023] In order to grip the stirrups 12, the grip elements 51 are moved by the double-stroke
grip actuator 70 into a grip position formed by the abutment of the roller 59 on the
stirrup bending machine 2, with the beak 52 open onto a corresponding portion of the
stirrup 12 (Figure 2).
[0024] In the illustrated case, the grip elements 51 grip two stirrups 12, which are provided
simultaneously by the stirrup bending machine 2, which is of the so-called twin-rod
type. However, it is evident that the apparatus can operate likewise with a single
stirrup 12 or with multiple stirrups 12, depending on the characteristics of the stirrup
bending machine 2.
[0025] The beak 52 is then closed by way of the actuator 54 in order to clamp said portion
of the stirrups 12 (Figure 3). It should be noted that the elastic support of the
actuator 54, by means of the stem 56, which can slide in contrast with the elastic
means 57, causes by reaction the movement of the bracket 55 and accordingly causes
the automatic centering of the stirrups 12 on the grip elements 51. Clearly, it is
possible to use other different grip systems.
[0026] This allows to adapt to the position of the stirrups 12 which, due to imperfect working,
to flexing under their own weight and to the dynamic nature of the process, can easily
not be in the theoretically expected position.
[0027] For this purpose, it has been found that the best way to grip the stirrups is to
fasten the clamps sequentially rather than all simultaneously. A particular stirrup
closure sequence has therefore been devised which offers the best results and allows
to prevent said stirrups from being gripped and then locked in a position that is
deformed due to the elasticity of the material, which undergoes deformation due to
its own weight.
[0028] The particular sequence, in the case shown in Figure 1, entails gripping the lower
portion of the stirrup, then the lateral portion that lies opposite the closing overlap
of the stirrup, and finally the other lateral portion.
[0029] After the stirrups 12 have been gripped by the grip elements 51, said stirrups 12
are cut by the conventional cutting elements of the stirrup bending machine 2. The
stirrups 12 gripped by the grip elements 51 are then moved in a longitudinal direction
by the actuation of the corresponding double-stroke actuators 70 or the like, until
a preset working position (Figure 4) is reached.
[0030] At this point, the actuation of the welding means 80, preset in said working position,
is activated. In particular, first the lifting of the movable welding units 81 on
the part of the actuator 84 is activated (Figure 5), followed by a suitable retraction
stroke of the grip elements 51 actuated by the actuator 70, in order to place the
stirrups 12 at said movable welding units 81 (Figure 6).
[0031] The stirrups 12 are then gripped between the welding units 81 and 82 and released
by the grip elements 51, which advance again, by a limited extent, in order to disengage
from said stirrups 12 (Figure 7). It should be noted that in this step the welding
units 81 and 82 do not clamp the stirrups 12 fully, but close only to the extent sufficient
to prevent only the fall of the stirrups 12, or as an alternative it is possible to
provide additional stirrup retention elements, for example of the mechanical or magnetic
type or the like.
[0032] The grip elements 51 are then moved into a lowered position by means of the actuation
of the second actuator 61, in order to allow the return stroke of said grip elements
51 without interfering with the subsequent working steps of the welding means 80 (Figure
8).
[0033] It is therefore possible to actuate the movement of the welding means 80 to a forward
position by way of the traction unit carried by the enclosure 74, monolithically provided
with the body 67 through which the guiding shafts 66 of the grip elements 51 can slide
(Figure 9). This advancement is actuated by the rotary actuation of the gear 73, which
is coupled to the rack 76 rigidly coupled to the enclosure 74. This determines the
traction of the stirrups 12, which advance while resting on the platform 3. During
this step, it is advisable to block the longitudinal rods 11 by way of known means
in order to prevent said rods from being drawn forward due to the friction generated
with the stirrup and with the grip elements themselves.
[0034] During said traction step, the return stroke of the grip elements 51 is also performed
through the actuation of the double-stroke actuator 70.
[0035] More specifically, the welding means 80 initially place the first pair of stirrups
12 at a preset position, starting from which the pack 10 is formed. In this preset
position, said stirrups 12 are clamped by the welding units 81 and 82 and are welded
to the auxiliary rods 11, which are simultaneously fed in a longitudinal direction
outside said stirrups 12.
[0036] The welding means 80 then perform a return stroke to the preceding active position
in order to pick up a subsequent pair of stirrups 12 from the picking elements 51,
which in the meantime have in turn picked up said pair of stirrups 12 from the input
region E of the stirrup bending machine 2, in the manner described earlier.
[0037] Said subsequent pair of stirrups 12 picked up by the welding means 80 is transferred
into a forward position adjacent to the first pair of stirrups 12, which is moved
to said preset position and there welded likewise to the auxiliary rods 11.
[0038] In a similar manner, the subsequent pairs of stirrups 12 are picked up and transferred
until the intended pack 10 is completed. These pairs of stirrups 12 are respectively
arranged adjacent to the ones transferred and welded previously, so that the welding
means 80 perform strokes of gradually decreasing breadth during the forming of the
pack 10.
[0039] Therefore, by means of a series of successive cycles of advancement and return of
the grip elements 51 and of the welding means 80, a plurality of stirrups 12 is welded
to the auxiliary rods 11, so as to form the pack 10. The mutual distance between the
stirrups 12 is generally limited and is preferably such as to arrange said stirrups
tidily and equidistantly in contact with each other. For example, if the stirrups
12 have a closed profile with overlapping ends, as shown in Figure 1, said distance
is substantially equal to the diameter of the rod.
[0040] The auxiliary rods 11 are constituted by rods that have any cross-section and are
preferably narrower than the stirrups 12. Of course, in addition to having a circular
cross-section, the auxiliary rods 11 can have a flattened shape or other similar shapes.
It is further possible to provide on the auxiliary rods 11 suitable shaped portions
or distinctive elements of any kind, for example a series of suitably spaced recesses.
[0041] It should be noted that since the auxiliary rods 11 are preferably narrow with respect
to the stirrups 12, said stirrups are not affected by the welding step, which instead
causes the local melting of the auxiliary rods 11 alone.
[0042] Conveniently, the auxiliary rods 11 are welded to the stirrups 12 so as to allow
their easy separation subsequently, when the stirrups 12 are used. The welding can
affect only some of the stirrups 12 that are arranged mutually adjacent so as to form
the pack 10 or can be very limited. It is obvious, however, that at least the first
and last stirrups 12 of the pack 10 are necessarily welded to the auxiliary rods 11.
[0043] The pack 10 thus formed is moved away from the platform 3 after cutting the auxiliary
rods 11. During the welding step, provisions can be made to provide a weakening of
the auxiliary rods 11 at the last stirrup 12 of the pack 10, so as to produce the
cutting of said rods 11 through a suitable traction applied to the pack 10, without
having to resort to cutting elements.
[0044] According to a different embodiment of the method according to the invention, it
is possible to move stepwise the pack being formed instead of varying the stroke of
the welding means 80 during the successive forward and return cycles.
[0045] In this case, after the stirrups 12 have been gripped between the welding units 81
and 82 and the grip elements 51 have moved into the lowered position (see Figure 8
again), the welding means 80 are moved into a fixed forward position, in which the
stirrups 12 are clamped by the welding units 81 and 82 and welded to the auxiliary
rods 11. Then a further limited advancement stroke of the welding means 80 is actuated,
so as to clear said fixed position in order to allow the subsequent work cycle.
[0046] In practice, at each cycle the welding means 80 first move the pair of picked-up
stirrups 12 closer to the already-formed pack, and then weld said stirrups 12 to the
auxiliary rods 11 and produce the advancement of the entire pack 10 by one step, in
order to clear said fixed position, which in the examples cited above is substantially
equal in extent to the diameter in the case of open stirrups and substantially equal
to twice the diameter for closed stirrups in which there is an overlap. The stepwise
advancement of the pack 10 being formed of course causes the corresponding traction
of the auxiliary rods 11 welded to the stirrups 12.
[0047] During the step in which the stirrups 12 move toward the pack being formed, the auxiliary
rods 11 can be retained by suitable locking means. Furthermore, welding can be performed
during motion or in stationary conditions.
[0048] As an alternative, it is possible to provide relative motion between the welding
means 80 and the pack 10 being formed through a retrograde movement of the auxiliary
rods 11, which is actuated by suitable traction means or by way of the corresponding
spools or by acting on the pack of stirrups itself being formed and by taking up the
excess rod that is produced, by way of means that are suitable for the purpose.
[0049] In summary, the method and the apparatus according to the invention allow to form
automatically packs of stirrups for reinforced concrete, eliminating the need for
the operator to pick up the stirrups that exit from the stirrup forming machine, tidy
them up and bind them in a pack. This clearly allows to optimize the productivity
of the machines in addition to freeing the operator from an awkward and potentially
dangerous task.
[0050] It should be noted that the auxiliary rods 11 can be joined to the stirrups 12 by
way of any type of coupling, particularly by means of any welding method. The rods
11 can be on any side of the stirrups 12, and there may be even more than one rod
per side, according to the requirements. Moreover, the method for moving the frame
being formed may also be any, by traction or pushing, for example by using traction
wheels integrated in the straightening unit.
[0051] It should also be noted that the cited results are achieved by means of an apparatus
that has a structure that is simple in concept, safely reliable in operation, and
versatile in use.
[0052] The shape of the stirrups 12 can in fact be of any kind, even a very complex one.
By way of example, Figure 10 illustrates a pack that is formed with stirrups that
have an open configuration. In this case, since the stirrups do not have overlapping
portions, it is possible to arrange the stirrups in close contact with each other.
Figure 11 instead shows a pack that is formed with closed stirrups that have a more
complex geometry.
[0053] In the practical embodiment of the invention, the materials used, as well as the
shape and the dimensions, may be any according to requirements.
[0054] The disclosures in Italian Patent Applications No. B02002A000438 and No. B02002A000652
from which this application claims priority are incorporated herein by reference.
[0055] Where technical features mentioned in any claim are followed by reference signs,
those reference signs have been included for the sole purpose of increasing the intelligibility
of the claims and accordingly such reference signs do not have any limiting effect
on the interpretation of each element identified by way of example by such reference
signs.
1. A method for forming packs of stirrups,
characterized in that it comprises the steps of:
(a). arranging at least one first stirrup (12) at a front input region (E) of an apparatus
for forming packs of stirrups;
(b). picking up said first stirrup (12) from said front input region (E) by way of
grip and welding means (5) that can move along a longitudinal direction with respect
to said input region (E);
(c). producing the alternating movement of said grip and welding means (5) into a
forward position for the drawing of said first stirrup (12) at said forward position;
(d). fixing at least one longitudinal auxiliary rod (11) externally to said first
stirrup (12), which is retained by said grip and welding means (5);
(e). arranging adjacent to said first stirrup (12) drawn into said forward position
a series of additional stirrups (12), picked up in succession by said grip and welding
means (5) at said input region (E), so as to form a pack (10) of stirrups (12);
(f). fixing said longitudinal auxiliary rod (11) externally to at least one last stirrup
(12) of said pack (10);
(g). cutting said auxiliary rod (11) ahead of said pack (10) thus formed, or creating
a gap to space the next pack to be formed.
2. The method according to claim 1, characterized in that said steps of: (b). picking up said first stirrup (12) from said front input region
(E) and (e). arranging adjacent to said first stirrup (12) a series of additional
stirrups (12), entail picking in succession said stirrups (12) by way of grip means
(51) and transferring in succession said stirrups (12) to welding means (80), which
are associated with said grip and welding means (5).
3. The method according to claim 2, characterized in that it entails transferring said first stirrup (12) into said forward position and the
arrangement of said additional stirrups (12) adjacent to said first stirrup (12) by
way of said welding means (80), with a suitable timing with respect to the picking
of said stirrups (12) by said grip means (51) at said front input region (E).
4. The method according to claim 3, characterized in that it entails simultaneously moving said welding means (80) into said forward position
by actuation of the traction means (74) and producing the return stroke, in the opposite
direction, of said grip means (51) at said front input region (E), by actuation of
corresponding grip actuation means (70).
5. The method according to claim 1, characterized in that it entails arranging in succession said stirrups (2) to be picked up on a working
surface of a stirrup bending machine (2) that faces said front input region (E).
6. The method according to claim 5, characterized in that it entails gripping said stirrups (12) at said working surface of said stirrup bending
machine (2), by way of grip elements (51) that are associated with said grip and welding
means (5), before the step for cutting said stirrups (12) from the material from which
they are obtained by bending.
7. The method according to claim 6, characterized in that said grip means (51) grip said stirrups (12) according to a sequence.
8. The method according to claim 7, characterized in that said sequence entails gripping first the lower portion of said stirrups (12) and
then the lateral portion that lies opposite the closure overlap of said stirrups (12)
and finally the other lateral portion.
9. The method according to claim 1, characterized in that said step of: (e). arranging adjacent to said first stirrup (12) drawn into said
forward position a plurality of additional stirrups (12) entails transferring in succession
said stirrups (12) to welding means (80) that are associated with said gripping and
welding means (5), and performing in succession the alternating movement of said welding
means (80) with strokes of gradually decreasing breadth during the forming of said
pack (10).
10. The method according to claim 1, characterized in that said step of: (f). fixing said auxiliary rod (11) to said last stirrup (12) entails
the provision, during welding, of a weakening of said auxiliary rod (11) at said last
stirrup (12), so as to then cut said auxiliary rod (11) through a traction applied
to said pack (10).
11. The method according to claim 1, characterized in that said step of: (e). arranging adjacent to said first stirrup (12) a series of additional
stirrups (12) picked up in succession by said grip and welding means (5) entails moving
in succession said additional stirrups (12) into a fixed forward position, in which
said stirrups (12) are welded to said auxiliary rod (11), and then actuating an additional
stroke of said gripping and welding means (5) of limited extent, such as to produce
the stepwise advancement of said pack (10) being formed and clear said fixed position
in order to allow the next working cycle.
12. The method according to claim 11, characterized in that said stepwise advancement of said pack (10) being formed causes the corresponding
traction of said auxiliary rod (11) welded to said stirrups (12).
13. An apparatus for forming packs of stirrups, characterized in that it comprises: a front input region (E), in which a series of stirrups (12) is adapted
to be fed in succession; gripping and welding means (5), which can move along a longitudinal
direction with respect to said input region (E) and are adapted to pick up in succession
said stirrups (12) from said front input region (E) and be actuated with an alternating
motion in order to arrange said stirrups (12) mutually adjacent in a forward position,
so as to form a pack (10) of stirrups (12); welding means (80), which are associated
with said gripping and welding means (5) and are adapted to fix a longitudinal auxiliary
rod (11) externally at least to first and last stirrups (12) of said pack (10).
14. The apparatus according to claim 13, characterized in that said gripping and welding means (5) can move in a longitudinal direction that is
substantially perpendicular to a vertical plane traced by said input region (E).
15. The apparatus according to claim 13, characterized in that said gripping and welding means (5) comprise grip means (51), which are constituted
by a clamp (52) adapted to be actuated by a linear actuator (54) and is directed toward
said input region (E).
16. The apparatus according to claim 15, characterized in that said clamp (52) is actuatable by said actuator (54) in abutment against a bracket
(55), which is rigidly coupled to a stem (56) that is guided so that it can slide
in contrast with elastic means (57) through a sliding block (58).
17. The apparatus according to claim 16, characterized in that the floating support of said actuator (54) by way of said stem (56), which can slide
in contrast with said elastic means (57), is suitable to produce by reaction the movement
of said bracket (55) for the automatic centering of said stirrup (12) on said grip
means (51).
18. The apparatus according to claim 16, characterized in that said sliding block (58) is rigidly coupled to the stem (60) of a second linear actuator
(61), which is actuatable to move said grip means (51) into a lowered disengagement
position.
19. The apparatus according to claim 18, characterized in that said second linear actuator (61) is rigidly coupled to horizontal stems (66), which
pass slidingly through a body (67) that is rigidly coupled to traction means (74)
and are actuatable by a grip actuator (70).
20. The apparatus according to claim 13, characterized in that said welding means (80) comprise movable welding units (81), which are supported
by an arm (83), actuatable by a linear actuator (84), and cooperate with fixed welding
units (82), which are mounted on a body (85) that is supported in front of traction
means (74).
21. The apparatus according to claim 20, characterized in that said traction means (74) are constituted by an enclosure that is guided so that it
can slide along said longitudinal direction and is monolithically provided with a
longitudinal rack (76) that is coupled to a corresponding gear (73) driven by suitable
motor elements.
22. The apparatus according to claim 13, characterized in that said gripping and welding means (5) are supported by a working head (1), whose position
is adjustable on a chassis arranged in front of said input region (E).
23. The apparatus according to claim 13, characterized in that said auxiliary rod (11) unwinds from a spool that is arranged to one side of a platform
(3) on which said pack (10) of stirrups (12) is formed.
24. A pack of stirrups, characterized in that it comprises a series of stirrups (12) arranged side by side and coupled to each
other by at least one longitudinal auxiliary rod (11) that is welded externally at
least to the first and last of said stirrups (12).
25. The pack according to claim 24, characterized in that said stirrups (12) are arranged equidistantly and mutually adjacent.
26. The pack according to claim 25, characterized in that all of said stirrups (12) are welded to said longitudinal auxiliary rod (11).