Intelligent material distribution system and method for ballastless track

Abstract

The invention discloses an intelligent material distribution method for a ballastless track. The intelligent material distribution method comprises the following steps of feeding and storage, butt joint of a hopper and a pouring opening, discharging control and discharging stop control. According to the intelligent material distribution method for the ballastless track, operation is convenient, working condition data in the pouring process are monitored in real time, the pouring effect of the base plate and the track plate can be visually obtained through an information platform interface, it can be ensured that self-compacting concrete slurry completes extrusion and push type discharging in the flowing process through hopper simulation design and use, and the construction efficiency is improved. The pouring quality is improved, and the problem that the ballastless track pouring forming material distribution effect is poor is solved; in addition, interlocking control is carried out on feeding storage, butt joint of the hopper and the pouring opening, discharging control and discharging stop control, and the intelligent high-quality pouring construction production requirement can be met.

Description

Technical Field

[0001] The present invention relates to the technical field of ballastless track production, and in particular to an intelligent ballastless track material laying system and method. Background Art

[0002] During the construction of ballastless track, concrete pouring of the base plate and track plate is required. However, in the actual concrete pouring process, manual construction is still the main method, lacking automated mechanical equipment that matches the structural type. The site often presents "extensive" pouring construction, with the material spreader "randomly" moving the pump pipe to spread the material, and the vibrator vibrating in a disorderly manner to "drive the material point by point". The actual flow distance of the concrete is generally long, and the homogeneity varies greatly. In addition, this type of construction method has certain safety hazards.

[0003] Therefore, the existing ballastless track casting and forming fabric effect is poor and cannot meet the intelligent high-quality casting construction production requirements. Summary of the invention

[0004] The object of the present invention is to provide an intelligent material distribution system and method for ballastless track, which are used to solve the problem of poor material distribution effect of casting and forming of ballastless track in the prior art.

[0005] The purpose of the present invention can be achieved through the following technical solutions:

[0006] A ballastless track intelligent laying method comprises the following steps:

[0007] S1. Material loading and storage: the self-compacting concrete slurry is loaded into the concrete tank truck by a pump truck, and the tank body of the concrete tank truck stirs and stores the self-compacting concrete slurry;

[0008] S2, the hopper is connected to the pouring port, the concrete tank truck drives to the pouring port, and the hopper docking port is adjusted by the three-dimensional six-degree-of-freedom adjustment device. After the hopper bottom is connected to the pouring port, unloading begins;

[0009] S3, discharge control, remote control the mixing and discharging handle of the tank body, discharge the self-compacting concrete slurry into the hopper, open the gate of the hopper for pouring, and during pouring, convert the pouring simulation experiment calculation model into an intuitive information platform interface to ensure that the self-compacting concrete slurry is discharged in a squeeze-push manner during the flow process, thereby improving the pouring quality;

[0010] S4, unloading stop control, a liquid flow sensor is provided on the bottom surface of the casting plate, through which the flow of the self-compacting concrete slurry under the plate is monitored in real time. When the self-compacting concrete slurry flows out evenly from the four discharge ports at the bottom of the plate, the overflow sensor at the discharge port position sends out an alarm command and stops unloading.

[0011] As a further solution of the present invention: when the tank body of the concrete tank truck stirs and stores the self-compacting concrete slurry in step S1, the stirring speed of the tank body can be adjusted and controlled to achieve adjustable control of the unloading speed of the self-compacting concrete slurry, ensuring that the self-compacting concrete slurry does not segregate before pouring.

[0012] As a further solution of the present invention: when the hopper docking port is adjusted by the three-dimensional six-degree-of-freedom adjustment device in step S2, a position sensor is provided at the bottom discharge end of the hopper, and the position sensor is used to detect whether the docking between the hopper bottom and the filling port is completed.

[0013] As a further solution of the present invention: when the position sensor detects that the bottom opening of the hopper is connected to the filling port, the detection signal is fed back to the control unit, and the control unit sends a start unloading instruction to the tank discharge port valve.

[0014] As a further solution of the present invention: when the self-compacting concrete slurry is discharged into the hopper in step S3, a flow rate sensor is provided at the discharge port of the tank body, and the discharge speed of the self-compacting concrete slurry is detected in real time by the flow rate sensor.

[0015] As a further solution of the present invention: a pressure sensor is provided on the gate of the hopper, and the pressure sensor is used to detect whether the self-compacting concrete slurry flowing into the hopper meets the preset pouring volume, and the gate of the hopper is opened for pouring.

[0016] As a further solution of the present invention: the structure of the hopper in step S3 satisfies the design of the fluid-solid coupling model to ensure the buoyancy pressure and contact area of ​​the self-compacting concrete slurry.

[0017] As a further solution of the present invention: when the gate of the hopper is opened for pouring, the material discharge flow rate of the hopper is controlled by adjusting the gate according to the hopper capacity to prevent air from entering the inner cavity of the track plate.

[0018] As a further solution of the present invention: in step S4, when the flow of the self-compacting concrete slurry under the plate is monitored in real time by the liquid flow sensor, the information platform interface can draw a discharge time and flow rate curve of the self-compacting concrete slurry to ensure a stable pouring process.

[0019] An intelligent ballastless track laying system, comprising:

[0020] A material distribution device, used for connecting with the filling port to discharge materials;

[0021] A detection unit is used to detect the temperature and humidity data of the self-compacting concrete slurry, the flow rate data of the self-compacting concrete slurry at the tank discharge port, the pressure data of the self-compacting concrete slurry flowing into the hopper, the flow rate data of the self-compacting concrete slurry under the casting plate, and the overflow data of the discharge ports at the four corners of the casting plate;

[0022] A control unit, used for adjusting the material distribution device docking interface through a three-dimensional six-degree-of-freedom adjustment device, and for performing signal transmission connection with the detection unit through the communication unit;

[0023] Among them, when the distribution device detects the completion of docking with the pouring port through the position sensor arranged at the bottom discharge end thereof, the control unit realizes intelligent automatic discharge control of the self-compacting concrete slurry according to the detection data obtained by the detection unit.

[0024] Beneficial effects of the present invention:

[0025] (1) During the use of the intelligent ballastless track laying method of the present application, the working condition data during the pouring process is monitored in real time, and the pouring effects of the base plate and the track plate can be intuitively obtained through the information platform interface. The hopper simulation design can ensure that the self-compacting concrete slurry is discharged in an extrusion-pushing manner during the flow process, thereby improving the pouring quality and solving the problem of poor pouring effect of ballastless track casting;

[0026] (2) During the use of the intelligent ballastless track laying method of the present application, the material storage, the docking of the hopper and the pouring port, the unloading control and the unloading stop control in the present application are all interlocked and controlled, which can realize the intelligent high-quality pouring construction production requirements;

[0027] (3) During the use of the ballastless track intelligent distribution system of the present application, intelligent automatic unloading control of self-compacting concrete slurry is realized, which helps to improve the pouring quality and solve the problem of poor distribution effect of ballastless track casting and forming; in addition, the distribution device, detection unit and control unit in the present application are interlocked and controlled to meet the production needs of intelligent high-quality casting construction. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The present invention will be further described below in conjunction with the accompanying drawings.

[0029] Figure 1 It is a flow chart of an intelligent laying method for ballastless track of the present invention;

[0030] Figure 2 It is a framework diagram of an intelligent material laying system for ballastless track of the present invention;

[0031] Figure 3 yes Figure 1 Schematic diagram of the simulation of the self-compacting discharging state of the hopper in the discharging control step;

[0032] Figure 4 yes Figure 1 Schematic diagram of monitoring the self-compacting discharge time and flow rate curve in the discharge control step.

[0033] In the figure: 10, control unit; 20, material distribution device; 30, communication unit; 40, detection unit. DETAILED DESCRIPTION

[0034] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0035] In the description of the present invention, it should be understood that the terms indicating orientation or positional relationship are based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention; in the description of the present invention, the meaning of "multiple" and "several" is at least two, for example two, three, etc., unless otherwise clearly and specifically defined.

[0036] See also Figure 1 As shown, the present invention is an intelligent laying method for ballastless track, comprising the following steps:

[0037] S1. Material loading and storage: The self-compacting concrete slurry is loaded into the concrete tank truck by pumping material from a pump truck. The tank body of the concrete tank truck mixes and stores the self-compacting concrete slurry. The self-compacting concrete slurry used matches the performance parameters of the ballastless track.

[0038] In this step, when the tank body of the concrete tank truck stirs and stores the self-compacting concrete slurry, the tank body stirring speed can be adjusted and controlled to achieve adjustable control of the self-compacting concrete slurry unloading speed, ensuring that the self-compacting concrete slurry does not segregate before pouring.

[0039] S2. The hopper is connected to the pouring port. The concrete tank truck drives to the pouring port and adjusts the hopper connection port through a three-dimensional six-degree-of-freedom adjustment device. After the hopper bottom is connected to the pouring port, unloading begins.

[0040] In this step, when the hopper docking port is adjusted by the three-dimensional six-degree-of-freedom adjustment device, a position sensor is provided at the bottom discharge end of the hopper, and the position sensor is used to detect whether the docking between the hopper bottom and the filling port is completed.

[0041] When the position sensor detects that the bottom of the hopper is connected to the filling port, the detection signal is fed back to the control unit 10, and the control unit 10 sends a start unloading instruction to the tank discharge port valve.

[0042] like Figure 3As shown in FIG. 1 , the structure of the hopper in this step satisfies the design of the fluid-solid coupling model, ensuring the buoyancy pressure and contact area of ​​the self-compacting concrete slurry; when the gate of the hopper is opened for pouring, the hopper discharge flow rate is controlled by adjusting the gate according to the hopper capacity to prevent air from entering the inner cavity of the track plate; Figure 3 As shown, during the structural design of the hopper, the upper part of the hopper is a wide-diameter cylindrical shape, the middle part is a cone shape, and the lower part is a narrow-diameter cylindrical shape, so that the designed hopper can meet the requirements of the self-compacting concrete slurry in the process of flowing in an extrusion-pushing manner.

[0043] S3. Discharging control: remotely control the mixing and discharging handle of the tank to discharge the self-compacting concrete slurry into the hopper, open the gate of the hopper for pouring. During pouring, the pouring simulation experiment calculation model is converted into an intuitive information platform interface to ensure that the self-compacting concrete slurry is discharged in an extrusion-pushing manner during the flow process, thereby improving the pouring quality.

[0044] When the self-compacting concrete slurry is discharged into the hopper in this step, a flow rate sensor is provided at the discharge port of the tank body, and the discharge speed of the self-compacting concrete slurry is detected in real time by the flow rate sensor.

[0045] A pressure sensor is provided on the gate of the hopper, which detects whether the self-compacting concrete slurry flowing into the hopper meets the preset pouring volume through the pressure sensor, and opens the gate of the hopper for pouring.

[0046] S4, unloading stop control, a liquid flow sensor is provided at the bottom of the casting plate, through which the flow of the self-compacting concrete slurry under the plate is monitored in real time. When the self-compacting concrete slurry flows out evenly from the four discharge ports at the bottom of the plate, the overflow sensor at the discharge port sends out an alarm command and stops unloading.

[0047] like Figure 4 As shown, in this step, when the flow of the self-compacting concrete slurry under the plate is monitored in real time by the liquid flow sensor, the information platform interface can draw the discharge time and flow rate curve of the self-compacting concrete slurry to ensure a stable pouring process.

[0048] In this specific implementation, when the overflow sensor at the discharge port detects that the self-compacting concrete slurry is overflowing, the on-site operating workers can fill and seal the four corners according to the flashing lights; after the sealing is completed, the hopper can be controlled to stop unloading, and the hopper can be raised to separate the pouring port; after one pouring is completed, the hopper returns to its position (while observing the weight data of the self-compacting concrete slurry in the hopper to determine whether the pouring amount of the next track is met and communicated and handled in time), the tank truck drives to the next pouring port, and repeats the pouring process; after the concrete pouring work is completed, the vehicle drives to the designated position and height to clean and treat wastewater and waste, and dumping is strictly prohibited.

[0049] The intelligent ballastless track laying method of the present application is easy to operate, and can monitor the working condition data during the pouring process in real time. The pouring effects of the base plate and the track plate can be intuitively obtained through the information platform interface. The hopper simulation design and use can ensure that the self-compacting concrete slurry is discharged by squeezing and pushing during the flow process, thereby improving the pouring quality and solving the problem of poor ballastless track casting and forming laying effect. In addition, in the present application, the material loading storage, the docking of the hopper and the pouring port, the unloading control and the unloading stop control are all interlocked and controlled, which can meet the intelligent high-quality pouring construction production needs.

[0050] like Figure 2 As shown, the present invention also provides an intelligent ballastless track distribution system, including a distribution device 20, a detection unit 40 and a control unit 10; the distribution device 20 is used to connect with the pouring port for unloading; the detection unit 40 is used to detect the temperature and humidity data of the self-compacting concrete slurry, the flow rate data of the self-compacting concrete slurry at the tank discharge port, the pressure data of the self-compacting concrete slurry flowing into the hopper, the flow rate data of the self-compacting concrete slurry under the casting plate and the overflow data of the discharge port at the four corners of the casting plate; the control unit 10 is used to adjust the connection interface of the distribution device 20 through a three-dimensional six-degree-of-freedom adjustment device, and is used to connect with the detection unit 40 for signal transmission through the communication unit 30.

[0051] When the material distribution device 20 detects that the connection with the pouring port is completed through the position sensor arranged at the bottom discharge end thereof, the control unit 10 realizes the intelligent automatic discharge control of the self-compacting concrete slurry according to the detection data obtained by the detection unit 40.

[0052] It should be understood that the material distribution device 20 in the present application is a hopper, and the structural design of the hopper is consistent with the hopper used in the above method, which will not be described in detail; the detection data obtained in the detection unit 40 can be detected and obtained by the sensor arranged accordingly.

[0053] During the use of the ballastless track intelligent distribution system of the present application, intelligent automatic unloading control of self-compacting concrete slurry is realized, which helps to improve the pouring quality and solve the problem of poor distribution effect of ballastless track casting and forming; in addition, the distribution device 20, the detection unit 40 and the control unit 10 in the present application are interlocked and controlled to meet the intelligent high-quality casting construction production needs.

[0054] It should be understood that all or part of the steps of implementing the above method embodiment can be completed by hardware related to program instructions, and the above program can be stored in a computer-readable storage medium. When the program code is called by the processor, the processor is used to execute the control method executed in the above method embodiment. The embodiment of the present invention does not limit the form and number of the memory and the processor. For example, the memory can be a CPU or other processor that can call a program, and the memory can be a read-only memory ROM, a random access memory RAM, a disk or an optical disk, and other media that can store program codes.

[0055] The above is a detailed description of an embodiment of the present invention, but the content is only a preferred embodiment of the present invention and cannot be considered to limit the scope of implementation of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the scope of the patent coverage of the present invention.

Claims

1. An intelligent laying method for ballastless track, characterized in that: The following steps are involved: S1. Material loading and storage: the self-compacting concrete slurry is loaded into the concrete tank truck by a pump truck, and the tank body of the concrete tank truck stirs and stores the self-compacting concrete slurry; S2, the hopper is connected to the pouring port, the concrete tank truck drives to the pouring port, and the hopper docking port is adjusted by the three-dimensional six-degree-of-freedom adjustment device. After the hopper bottom is connected to the pouring port, unloading begins; S3, discharge control, remote control the mixing and discharging handle of the tank body, discharge the self-compacting concrete slurry into the hopper, open the gate of the hopper for pouring, and during pouring, convert the pouring simulation experiment calculation model into an intuitive information platform interface to ensure that the self-compacting concrete slurry is discharged in a squeeze-push manner during the flow process, thereby improving the pouring quality; S4, unloading stop control, a liquid flow sensor is provided on the bottom surface of the casting plate, through which the flow of the self-compacting concrete slurry under the plate is monitored in real time. When the self-compacting concrete slurry flows out evenly from the four discharge ports at the bottom of the plate, the overflow sensor at the discharge port position sends out an alarm command and stops unloading.

2. The intelligent laying method for ballastless track according to claim 1, characterized in that: When the tank body of the concrete tank truck stirs and stores the self-compacting concrete slurry in step S1, the stirring speed of the tank body can be adjusted and controlled to achieve adjustable control of the unloading speed of the self-compacting concrete slurry, ensuring that the self-compacting concrete slurry does not segregate before pouring.

3. The intelligent laying method for ballastless track according to claim 1 is characterized in that: When the hopper docking port is adjusted by the three-dimensional six-degree-of-freedom adjustment device in step S2, a position sensor is provided at the bottom discharge end of the hopper, and the position sensor is used to detect whether the docking between the hopper bottom and the filling port is completed.

4. The intelligent laying method for ballastless track according to claim 3 is characterized in that: When the position sensor detects that the docking between the bottom opening of the hopper and the filling port is completed, a detection signal is fed back to the control unit (10), and a discharge start instruction is sent to the tank discharge port valve through the control unit (10).

5. The intelligent laying method for ballastless track according to claim 1, characterized in that: When the self-compacting concrete slurry is discharged into the hopper in step S3, a flow rate sensor is provided at the discharge port of the tank body, and the discharge speed of the self-compacting concrete slurry is detected in real time by the flow rate sensor.

6. The intelligent laying method for ballastless track according to claim 5, characterized in that: A pressure sensor is provided on the gate of the hopper, and the pressure sensor is used to detect whether the self-compacting concrete slurry flowing into the hopper meets the preset pouring volume, and the gate of the hopper is opened for pouring.

7. The intelligent laying method for ballastless track according to claim 1, characterized in that: The structure of the hopper in step S3 satisfies the fluid-solid coupling model design, ensuring the buoyancy pressure and contact area of ​​the self-compacting concrete slurry.

8. The intelligent laying method for ballastless track according to claim 7, characterized in that: When the gate of the hopper is opened for pouring, the material discharge flow rate of the hopper is controlled by adjusting the gate according to the hopper capacity to prevent air from entering the inner cavity of the track plate.

9. The intelligent laying method for ballastless track according to claim 1, characterized in that: In step S4, when the flow of the self-compacting concrete slurry under the plate is monitored in real time by the liquid flow sensor, the information platform interface can draw a discharge time and flow rate curve of the self-compacting concrete slurry to ensure a stable pouring process.

10. An intelligent ballastless track laying system, characterized in that: include: A material distribution device (20) is used for connecting with the filling port to discharge the material; A detection unit (40) is used to detect temperature and humidity data of the self-compacting concrete slurry, flow rate data of the self-compacting concrete slurry at the tank discharge port, pressure data of the self-compacting concrete slurry flowing into the hopper, flow rate data of the self-compacting concrete slurry under the casting plate, and overflow data of the discharge ports at the four corners of the casting plate; A control unit (10) is used to adjust the docking interface of the material distribution device (20) through a three-dimensional six-degree-of-freedom adjustment device, and is used to establish a signal transmission connection with the detection unit (40) through the communication unit (30); When the material distribution device (20) detects that docking with the pouring port is completed through a position sensor provided at the bottom discharge end thereof, the control unit (10) implements intelligent automatic discharge control of the self-compacting concrete slurry based on the detection data acquired by the detection unit (40).

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