Formwork system, beam body production system and beam body production method

Abstract

The invention relates to the technical field of track beams, and provides a formwork system, a beam body production system and a beam body production method. The template system comprises a movable pedestal provided with a first track; the fixed seats are arranged on the two sides of the movable pedestal, and second rails are arranged on the fixed seats; the bottom die is fixed to the movable pedestal, and the first rails are located on the two sides of the bottom die; and the side mold can move from one of the first track and the second track to the other, and when the side mold moves to the first track, a cavity used for pouring a beam body is defined by the side mold and the bottom mold. According to the formwork system, the problem that in the prior art, too many formworks are needed for beam body production can be effectively solved, the number of the formworks on a production line is greatly reduced, and the production and manufacturing cost of track beams is reduced.

Description

Technical Field

[0001] The present application relates to the technical field of track beams, and in particular to a template system, a beam production system, and a beam production method. Background Art

[0002] In the existing technology, the production of track beams generally adopts a secondary tensioning process, and its process route is: the template is fixed to the mobile pedestal by bolts or other means, and the mobile pedestal drives the track beam and template to flow between various workstations to complete the manufacturing process.

[0003] The above production method has significant defects: since the template needs to go through all the production processes synchronously with the mobile pedestal, the number of templates required in the production process forms a fixed ratio with the number of mobile pedestals, that is, each set of mobile pedestals needs to be equipped with independent side molds, bottom molds and other template components, resulting in a significant increase in template usage.

[0004] The use of a large number of templates not only leads to excessively high production costs, but also the frequent transportation of templates between various workstations along with the mobile pedestal significantly increases the load-bearing weight and space occupied by the mobile pedestal, resulting in increased transportation energy consumption and increased equipment loss. Summary of the Invention

[0005] The present application provides a template system to solve the problem of excessive number of templates required for beam production in the prior art, significantly reduce the number of templates on the production line, and reduce the production cost of track beams.

[0006] The present application also provides a beam production system.

[0007] The present application also provides a beam production method.

[0008] According to a first embodiment of the present application, a template system includes: The movable platform is provided with a first track; A fixed base is provided on both sides of the movable base, and a second track is provided on the fixed base; A bottom mold is fixed on the movable base, and the first tracks are located on both sides of the bottom mold; The side form can be moved from one of the first track and the second track to the other. When the side form moves to the first track, the side form and the bottom form are surrounded to form a cavity for pouring the beam body.

[0009] According to one embodiment of the present application, the template system further includes a pushing mechanism disposed on the fixing seat, and the pushing mechanism is configured to drive the side template to move between the first track and the second track.

[0010] According to one embodiment of the present application, a slider that cooperates with the first rail and the second rail is provided at the bottom of the side mold.

[0011] According to a second aspect of the present application, a template system includes: mobile pedestal; A fixed seat is provided on both sides of the movable seat, and a second track is provided on the fixed seat; a running wheel is provided at the bottom of the fixed seat so that the fixed seat can move with the movable seat; A bottom mold is fixed on the movable base; The side formwork is movably mounted on the second track. When the side formwork approaches the bottom formwork along the second track, the side formwork and the bottom formwork enclose and form a cavity for casting the beam body.

[0012] According to a third aspect of the present application, a beam production system includes: A casting module, comprising the aforementioned formwork system, for closing the mold and casting the beam body; a steaming module, configured to steam-cure the beam body cast by the casting module; One of the casting module and the steaming module is further configured to demould the beam body after being steamed in the steaming module.

[0013] According to one embodiment of the present application, the steaming module includes: a first steaming chamber, configured to steam-cure the beam body cast by the casting module, wherein the casting module is used to demould the beam body after steaming in the first steaming chamber, or the beam body is demoulded in the first steaming chamber after steaming in the first steaming chamber; The second steaming chamber is configured to steam-cure the beam body that has been steamed in the first steaming chamber again.

[0014] According to one embodiment of the present application, the beam production system further includes a first transverse ferry module, which is configured to receive a mobile pedestal that is recycled after use for use by the casting module.

[0015] According to one embodiment of the present application, the first transverse ferry module is arranged upstream of the casting module, and the first transverse ferry module transports the movable platform to the casting module; or, the first transverse ferry module and the casting module are arranged at the same work station.

[0016] According to one embodiment of the present application, the beam production system also includes a second transverse ferry module, which is arranged downstream of the steaming module, and the second transverse ferry module is configured to move the mobile platform after use horizontally to the conveying line returning to the casting module.

[0017] According to one embodiment of the present application, the beam production system includes multiple production lines and at least one return line; The mobile pedestal cooperates with the production line so that the mobile pedestal drives the beam to complete the production process; the mobile pedestal cooperates with the return line so that the mobile pedestal returns to the casting module via the return line after use.

[0018] According to a fourth aspect of the present application, a beam production method using the aforementioned beam production system includes: pouring concrete into the formwork system; Transport the beam to the steam curing area for steam curing; Demoulding the beam after steam curing; Transport the beam to the steam curing area for steam curing again; The beam is tensioned once.

[0019] According to one embodiment of the present application, demolding the steam-cured beam body includes: The steam-cured beam is transported to the casting area for demoulding.

[0020] According to one embodiment of the present application, transporting the beam to the steaming area for steaming includes: The mobile pedestal carries the cast beam and formwork system to the steam curing area for the first steam curing of the beam.

[0021] According to one embodiment of the present application, the step of transporting the steam-cured beam to the casting area for demoulding includes: The mobile pedestal carries the beam body and the formwork system after the first steaming to the casting area for demoulding, and leaves the side formwork in the formwork system in the casting area, and the bottom formwork continues to move with the mobile pedestal.

[0022] According to one embodiment of the present application, demolding the steam-cured beam body includes: The steam-cured beam is demoulded in the steam-curing area.

[0023] According to one embodiment of the present application, transporting the beam to the steaming area for steaming includes: The mobile base and the fixed base carry the cast beam and formwork components to the steam curing area for the first steam curing of the beam.

[0024] According to one embodiment of the present application, demolding the steam-cured beam in the steam-curing area includes: After the movable pedestal and the fixed pedestal carry the cast beam and formwork assembly to complete steam curing in the steam curing area, the fixed pedestal carries the side formwork in the formwork assembly back to the casting area, and the bottom formwork continues to move with the movable pedestal.

[0025] According to one embodiment of the present application, before pouring concrete into the formwork system, the method further includes: The mold is closed in the casting area.

[0026] According to one embodiment of the present application, before the mold is closed in the casting area, the method further includes: The mobile base returns to the first transverse ferry area and adjusts its position to the position to be molded.

[0027] According to one embodiment of the present application, the first transverse ferry area is located upstream of the pouring area; The movable base returns to the first transverse ferry area and adjusts its position to the position to be molded, including: The movable platform returns to the first transverse ferry area, and is translated to a position corresponding to the production line of the casting area in the first transverse ferry area, and the movable platform is transported from the first transverse ferry area to the casting area.

[0028] According to one embodiment of the present application, the first transverse ferry area and the pouring area are arranged at the same workstation; The movable base returns to the first transverse ferry area and adjusts its position to the position to be molded, including: The movable platform returns to the first transverse ferry area and moves horizontally to the corresponding position of the production line in the first transverse ferry area.

[0029] According to one embodiment of the present application, the steaming area includes a first steaming area and a second steaming area; The method of transporting the beam to the steaming area for re-steaming includes: The beam is transported to the second steaming area for a second steaming.

[0030] According to one embodiment of the present application, the steam curing area includes a first steam curing area, a second steam curing area and a third steam curing area; The method of transporting the beam to the steaming area for re-steaming includes: Transport the beam to the second steaming area for a second steaming; The beam is transported to the third steaming area for the third steaming.

[0031] According to one embodiment of the present application, the step of tensioning the beam once includes: After the beam reaches the tensioning strength, the beam is transported to the second transverse ferry area and tensioned once.

[0032] According to one embodiment of the present application, after the beam body is tensioned once, the method further includes: The beam body is transported to the beam storage area through the second transverse ferry area; the mobile platform is moved horizontally through the second transverse ferry area to the return conveying line and returned to the casting area.

[0033] The above one or more technical solutions in the embodiments of the present application have at least one of the following technical effects: The formwork system in the present application is a non-completely fixed installation of the side formwork and the movable base, which is different from the existing bolt-fixed installation. When pouring is required, the side formwork enters the first track and forms a cavity for pouring the beam body with the bottom formwork fixedly installed on the movable base, and then the beam body is formed by pouring concrete. Before demolding, the side formwork and the bottom formwork remain stationary so that the beam body reaches the demolding strength; after the beam body is demolded, the side formwork is separated from the movable base, and the side formwork enters the second track. The side formwork does not need to enter the subsequent workstation with the movable base, which not only reduces the load-bearing weight of the movable base, but also greatly reduces the number of formworks (number of side formworks) required on the production line. Efficient production of track beams can be achieved with a smaller number of formworks, which greatly reduces the manufacturing cost of track beams.

[0034] Additional aspects and advantages of the present application will be given in part in the description below, and in part will become obvious from the description below, or will be learned through practice of the present application. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the technical solutions in the embodiments of the present application or related technologies, the following briefly introduces the drawings required for use in the embodiments or related technical descriptions. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0036] Figure 1 This is a schematic diagram of the structure of the template system provided by this application Figure 1 (Before mold closing).

[0037] Figure 2 for Figure 1 Enlarged view of the structure of part A in the middle.

[0038] Figure 3 This is a schematic diagram of the structure of the template system provided by this application Figure 2 (Pouring status).

[0039] Figure 4 This is a schematic diagram of the structure of the template system provided by this application Figure 3(The driving mechanism is separated from the side mold).

[0040] Figure 5 This is a schematic diagram of the structure of the template system provided by this application Figure 4 (After demoulding).

[0041] Figure 6 This is a schematic diagram of the structure of the template system provided by this application Figure 5 (In the first steaming room, steaming with molds).

[0042] Figure 7 This is a schematic diagram of the structure of the template system provided by this application Figure 6 (After demoulding, in the second steaming room or the third steaming room).

[0043] Figure 8 This is a schematic diagram of the structure of the template system provided by this application Figure 7 (Side view).

[0044] Figure 9 This is a schematic diagram of the structure of the beam production system provided by this application Figure 1 (The first transverse ferry module is arranged upstream of the casting module).

[0045] Figure 10 This is a schematic diagram of the structure of the beam production system provided by this application Figure 2 (The first transverse ferry module and the pouring module are set at the same work station).

[0046] Figure 11 This is a schematic diagram of the structure of another template system provided by this application Figure 1 (Pouring status).

[0047] Figure 12 This is a schematic diagram of the structure of another template system provided by this application Figure 2 (After demoulding).

[0048] Figure 13 This is a schematic diagram of the structure of another template system provided by this application Figure 3 (The part that returns to the pouring area).

[0049] Figure 14 This is a schematic diagram of the structure of the beam production system provided by this application Figure 3 (correspond Figure 12 and Figure 13 formwork system; the first transverse ferry module is arranged upstream of the pouring module).

[0050] Figure 15 It is a flow chart of the beam production method provided in this application.

[0051] Reference numerals: 1. Mobile pedestal; 11. First track; 2. Fixed seat; 21. Fixed pedestal; 22. Fixed support; 23. Second track; 24. Pushing mechanism; 3. Bottom mold; 4. Side mold; 41. Slider; 51. First transverse ferry area; 52. Casting area; 53. First steaming curing area; 54. Second steaming curing area; 55. Third steaming curing area; 56. Second transverse ferry area; 57. Beam storage area; 61. Production line; 62. Return line. DETAILED DESCRIPTION

[0052] The following embodiments of the present invention are described in further detail with reference to the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0053] In the description of the embodiments of the present application, it should be noted that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the embodiments of the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as limiting the embodiments of the present application. In addition, the terms "first", "second", and "third" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0054] In the description of the embodiments of this application, it should be noted that, unless otherwise specified or limited, the terms "connected" and "connection" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium. Those skilled in the art will understand the specific meanings of the above terms in the embodiments of this application based on the specific circumstances.

[0055] In the embodiments of the present application, unless otherwise expressly specified or limited, a first feature being "above" or "below" a second feature may mean that the first and second features are in direct contact, or that the first and second features are in indirect contact through an intermediate medium. Furthermore, a first feature being "above," "above," and "above" a second feature may mean that the first feature is directly above or obliquely above the second feature, or simply means that the first feature is higher in level than the second feature. A first feature being "below," "below," and "below" a second feature may mean that the first feature is directly below or obliquely below the second feature, or simply means that the first feature is lower in level than the second feature.

[0056] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the embodiments of the present application. In this specification, the schematic representations of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art can combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples, unless they are contradictory.

[0057] The existing beam production process requires distinct formwork operation areas for various operations. Each workstation requires auxiliary platforms, demolding reaction frames, and other features. The overall layout occupies a large area, requiring nine workstations, making it unsuitable for beam fabrication sites with limited space. Furthermore, to coordinate the various construction steps, a secondary tensioning process is required, making tensioning operations more complex. Furthermore, because all formwork is bolted to a mobile pedestal, each formwork must be moved with the pedestal. The number of formworks required must correspond to the number of mobile pedestals, resulting in numerous sets of formwork and high overall costs. Furthermore, because the formwork is mounted directly on the mobile pedestal, its heavy weight makes it difficult to hoist the entire structure, requiring a dedicated transverse shuttle vehicle for transverse movement and track change. Finally, because the formwork is permanently mounted on the mobile pedestal, all steam curing rooms must be designed to accommodate the maximum formwork dimensions. The large steam curing room space increases steam usage and construction costs.

[0058] According to a template system of the first embodiment of the present application, Figures 1 to 8 As shown, the formwork system includes: a movable base 1, which is provided with a first track 11; a fixed base 2, which is arranged on both sides of the movable base 1, and a second track 23 is provided on the fixed base 2; a bottom form 3, which is fixed on the movable base 1, and the first track 11 is located on both sides of the bottom form 3; a side form 4, which can be moved from one of the first track 11 and the second track 23 to the other, and when the side form 4 moves to the first track 11, the side form 4 and the bottom form 3 are surrounded to form a cavity for casting the beam body.

[0059] When the side form 4 moves to the first track 11, the side form 4 and the bottom form 3 enclose a cavity for casting the beam body; when the side form 4 moves to the second track 23, the side form 4 is separated from the movable base 1, and the side form 4 is no longer located on the movable base 1, and the side form 4 is no longer transported together with the movable base 1.

[0060] The fixed base 2 includes a fixed support 22 and a fixed pedestal 21. The fixed pedestal 21 can be the ground or other supporting foundation. The fixed support 22 is mounted on the fixed pedestal 21. The fixed support 22 can be a steel frame with a second track 23 provided on the steel frame. In the beam production process involved in the embodiment of the present application, the bottom mold 3 is always fixed on the movable pedestal 1.

[0061] It should be noted that, in some cases, the formwork system may also include end forms, wing plate forms, etc. The end forms and wing plate forms may be fixedly connected to the side forms 4 and move between the first track 11 and the second track 23 together with the side forms 4 .

[0062] The formwork system provided in the embodiment of the present application effectively solves the defects of the fixed formwork installation in the prior art through the design of movable side forms 4 and track structures. The movable pedestal 1 is provided with a first track 11, and the fixed seats 2 on both sides are provided with a second track 23. The bottom form 3 is fixed to the pedestal, and the side form 4 can be moved and switched between the two tracks: during casting, the side form 4 is enclosed with the bottom form 3 along the first track 11 to form a casting cavity, ensuring the closed space required for beam forming; after demolding, the side form 4 is separated from the movable pedestal 1 and moved to the second track 23 of the fixed seat 2, and no longer moves with the pedestal. This structure breaks through the limitations of the traditional bolt-fixed formwork and pedestal integration. The detachable design of the side form 4 significantly reduces the load-bearing weight of the movable pedestal 1, while reducing the overall space occupied by the pedestal when carrying the beam. It also greatly reduces the number of formwork required on the production line (the number of side formwork 4), achieving efficient production of track beams with a smaller number of formworks, and significantly reducing the manufacturing cost of track beams. Since the side mold 4 does not need to enter the subsequent workstation, the accompanying steaming room only needs to adapt to the compact size of "mobile base 1 + bottom mold 3 + beam body". Compared with the existing technology, the space of the steaming room can be greatly reduced, thereby reducing steam consumption and energy costs.

[0063] According to one embodiment of the present application, Figures 1 to 8 As shown, the template system further includes a pushing mechanism 24 disposed on the fixing seat 2 , and the pushing mechanism 24 is configured to drive the side template 4 to move between the first track 11 and the second track 23 .

[0064] In the embodiment of the present application, the pushing mechanism 24 is disposed on the fixed base 2 and enables automated switching of the side form 4 between the first track 11 and the second track 23, significantly improving the ease of operation and production efficiency of the formwork system. The pushing mechanism 24 precisely controls the movement trajectory of the side form 4 through mechanical drive (such as a hydraulic push rod or electric screw), eliminating the need for manual handling or adjustment, thus avoiding the time-consuming and labor-intensive positioning errors associated with traditional manual operations. During the casting process, the pushing mechanism 24 quickly pushes the side form 4 to the first track 11 and precisely aligns it with the bottom form 3, ensuring a precise seal in the casting cavity. After demolding, the pushing mechanism 24 automatically moves the side form 4 to the second track 23, separating it from the movable base 1 and facilitating the compact design of subsequent workstations. This automated side form 4 switching mechanism reduces operational errors caused by manual intervention and shortens workstation transition time. This synergistic effect, combined with the detachable side form 4 design, further optimizes the continuity of the track beam production process.

[0065] In specific applications, a displacement sensor can be configured for the pushing mechanism 24 to achieve precise positioning and intelligent linkage by real-time monitoring of the position of the side mold 4. For example, it can interact with the control system of the casting station to ensure that the casting process is automatically triggered after the side mold 4 is in place.

[0066] The pushing mechanism 24 can be an oil cylinder to provide a strong driving force; the pushing mechanism 24 can also be a pneumatic driving mechanism, which uses the flexible thrust of compressed air to achieve smooth movement of the side mold 4, adapting to the production environment with high requirements on noise and cleanliness; the pushing mechanism 24 can also be a foldable pushing arm, which retracts when not in use to save space and meet the compact layout requirements of the production line.

[0067] A buffer damping device can be integrated into the pushing mechanism 24 to reduce the impact vibration when the side mold 4 moves and improve the operating stability of the mechanism.

[0068] According to one embodiment of the present application, Figures 1 to 6 As shown, a slider 41 is provided at the bottom of the side mold 4 to cooperate with the first track 11 and the second track 23.

[0069] In this embodiment, a slider 41 disposed at the bottom of the side mold 4 cooperates with the first rail 11 and the second rail 23 to form a high-precision sliding guide mechanism, effectively enhancing the smoothness and positioning accuracy of the side mold 4 switching between different rails. The slider 41 forms a stable sliding connection by adapting to the shape of the rails (e.g., a convex rail-groove, T-rail-dovetail groove, etc.), significantly reducing frictional resistance during movement of the side mold 4 and enabling the side mold 4 to easily switch tracks under the action of the pushing mechanism 24.

[0070] During the pouring process, when the side form 4 slides along the first track 11 to the docking position with the bottom form 3 through the slider 41, the precise guiding function of the slider 41 can ensure the sealing fit between the side form 4 and the bottom form 3, avoiding leakage during the concrete pouring process and ensuring the dimensional accuracy of the beam body; after demolding, the side form 4 is moved to the second track 23 through the slider 41, leaving the load range of the mobile base 1. This process reduces the load pressure and mechanical loss of the mobile base 1 with the help of the low friction characteristics of the slider 41 and the track.

[0071] In practical applications, the durability of the slider 41 can be improved by optimizing the material (such as using wear-resistant engineering plastics or metal alloys), or the slider 41 can be used as a replaceable component to reduce maintenance costs and enhance the reliability of the production process.

[0072] Of course, the side mold 4 and the track can be connected not only by sliding but also by rolling. For example, rollers can be installed at the bottom of the side mold 4, and the side mold 4 can move on the track via the rollers. Alternatively, a rolling slider 41 (e.g., equipped with balls or rollers) can be directly used to replace the traditional sliding friction structure, converting sliding friction into rolling friction, further reducing energy consumption and increasing movement speed.

[0073] According to a second aspect of the present application, a template system is Figures 11 to 13 As shown, the formwork system includes: a movable base 1; a fixed base 2, which is arranged on both sides of the movable base 1, and a second track 23 is provided on the fixed base 2; a running wheel is provided at the bottom of the fixed base 2, so that the fixed base 2 can move with the movable base 1; a bottom form 3, which is fixed on the movable base 1; a side form 4, which is movably installed on the second track 23, and when the side form 4 approaches the bottom form 3 along the second track 23, the side form 4 and the bottom form 3 are surrounded to form a cavity for casting the beam body.

[0074] The formwork system of the second embodiment of the present application includes a movable base 1, fixed bases 2 disposed on both sides of the movable base 1, a bottom form 3 fixed to the movable base 1, and a side form 4 movably mounted on a second track 23 of the fixed base 2. The running wheels at the bottom of the fixed base 2 enable it to move synchronously with the movable base 1. When the side form 4 approaches the bottom form 3 along the second track 23, the side form 4 and the bottom form 3 enclose a cavity for casting the beam body. At this time, a slider 41 at the base of the side form 4 is used to cooperate with the second track 23.

[0075] During mold closing, the side mold 4 is precisely connected to the bottom mold 3 through the second track 23 to form a closed casting space, ensuring the forming accuracy of the beam body; during steam curing with the mold, the fixed base 2 and the mobile platform 1 transport the side mold 4 and the bottom mold 3 as a whole to the steam curing area, meeting the requirements of early concrete curing for formwork constraints; and after steam curing is completed and the demoulding strength is reached, the fixed base 2 can drive the side mold 4 to be directly separated from the mobile platform 1 in the steam curing area, and the fixed base 2 drives the side mold 4 back to the casting area to wait for the next mold closing; the mobile platform 1 does not need to return to the casting area, and carries the bottom mold 3 and the beam body directly into subsequent steam curing, tensioning and other processes, forming a process of "side mold 4 circulates with the fixed base 2 - mobile platform 1 one-way efficient transportation".

[0076] Compared to the formwork system of the first embodiment, this solution uses the running wheels of the fixed base 2 to synchronize the side formwork 4 with the mobile base 1 during the mold closing, pouring, and steaming stages, ensuring the integrity of the curing process. During the demolding process, the side formwork 4 is separated from the mobile base 1 along with the fixed base 2, and the formwork is separated directly in the steaming area, eliminating the need for the mobile base 1 to carry the beam back to the pouring area for demolding. This design reduces the round-trip transportation time of the mobile base 1, shortening the production cycle and reducing equipment energy consumption.

[0077] According to a beam production system of the third embodiment of the present application, Figure 9 and Figure 10 As shown, the beam production system includes: a casting module, including the aforementioned formwork system, the casting module is used to close the mold and cast the beam body; a steaming module, configured to steam the beam body cast by the casting module; one of the casting module and the steaming module is also configured to demold the beam body after steaming by the steaming module.

[0078] The beam production system organically integrates the casting module with the steam curing module. The casting module incorporates the aforementioned formwork system. The movable side formwork 4 between rails enables efficient transitions between the mold closing, casting, and demolding processes. During the mold closing phase, the side formwork 4 moves along the rails to mate with the bottom formwork 3 to form a closed casting cavity, ensuring precise concrete pouring. After pouring, the mobile platform 1 carries the beam, bottom formwork 3, and side formwork 4 into the steam curing module for curing. Once the beam reaches the demolding strength, it returns to the casting module for demolding. The mobile platform 1 then reenters the steam curing module, carrying only the beam and bottom formwork 3. This reduces the size requirements for subsequent steam curing areas within the steam curing module (such as the second and third steam curing chambers). Because the side formwork 4 has been released from the mobile platform 1 and moved onto the rails of the fixed platform 2 after demolding, the subsequent steam curing areas within the steam curing module only need to accommodate the compact structure of the mobile platform 1 + bottom formwork 3 + beam. This significantly reduces the steam curing space and steam consumption compared to traditional processes.

[0079] The casting module also performs the demolding function, avoiding the drawbacks of the traditional multi-station production process where the formwork frequently moves with the pedestal. This reduces process switching time and equipment wear, allowing the beam casting and demolding processes to be completed within the same module, significantly improving production efficiency. This modular design, through the integration of four detachable side molds with the process, not only ensures beam forming quality, but also reduces production costs through space utilization and process optimization, providing a highly efficient and energy-efficient technical solution for the industrialized production of rail beams.

[0080] Or, as Figure 14 As shown, another aforementioned formwork system can also be used to realize demoulding of the beam body in the steam curing module.

[0081] According to one embodiment of the present application, the steaming module includes: a first steaming chamber, which is configured to steam-cure the beam body cast by the casting module, and the casting module is used to demold the beam body after steaming in the first steaming chamber, or the beam body is demolded in the first steaming chamber after being steamed in the first steaming chamber; a second steaming chamber, which is configured to steam-cure the beam body steamed in the first steaming chamber again.

[0082] The steam curing module of the beam production system utilizes a hierarchical arrangement of primary and secondary steam curing chambers, forming an efficient curing system tailored to the formwork separation process. The primary steam curing chamber initially steam cures the entire "mobile pedestal 1 + beam + formwork" assembly, providing the temperature and humidity necessary for early strength development and achieving demolding strength. While the formwork remains attached to the mobile pedestal 1, the steam curing space (the primary steam curing chamber) must accommodate the formwork structure. However, after demolding, the formwork detaches from the mobile pedestal 1 and remains in the casting module. The "mobile pedestal 1 + bottom form 3 + beam" assembly then enters the primary and secondary steam curing chambers for curing. Since the secondary steam curing chamber does not need to adapt to formwork dimensions, its internal space can be precisely designed based on the actual specifications of the beam and mobile pedestal 1. This reduces the redundant space created by formwork compared to traditional single-curing chambers, significantly reducing steam consumption.

[0083] The phased steam curing model dynamically optimizes the curing space: the initial steam curing cycle takes into account the necessary space for formwork, while subsequent steam curing cycles eliminate the formwork footprint to reduce the cavity. This approach balances the need for the beam to bond with the formwork before demolding, while also allowing for a compact curing space after the formwork is separated. Furthermore, differentiated temperature and humidity parameters can be set for each of the two steam curing cycles. The initial cycle focuses on increasing temperature and maintaining moisture during the initial setting phase of the concrete, while the secondary cycle focuses on maintaining a constant temperature during the strength development phase. This avoids the adverse effects of a single curing parameter on beam performance and improves component quality and stability.

[0084] Or, as Figure 14 As shown, another aforementioned template system may also be used to enable the beam body to be demoulded directly in the first steaming chamber after steaming in the first steaming chamber is completed.

[0085] In practice, a third steam curing chamber can be added to form a three-stage curing process: the first steam curing chamber completes "steam curing with formwork" to achieve demolding strength for the beam, the second steam curing chamber performs "constant temperature curing for continuous strength growth," and the third steam curing chamber implements "final strength intensive curing." These three steam curing chambers can be set to different temperatures and humidity levels as needed, precisely matching the multi-stage requirements of concrete hydration. This is particularly suitable for curing long-span rail beams or those made of specialized materials. Each steam curing chamber independently controls parameters and is connected via automated transmission lines, enabling streamlined beam curing, reducing waiting time and improving equipment utilization.

[0086] According to one embodiment of the present application, Figure 9 and Figure 10 As shown, the beam production system also includes a first transverse ferry module, which is configured to receive the mobile pedestal 1 that is recycled after use for use by the casting module.

[0087] The first transverse ferry module, deployed within the beam production system, forms a recycling channel for the mobile pedestal 1 within the production process. It primarily receives the mobile pedestal 1 for recycling after demoulding and other processes. It then rapidly transports it to the ready-to-use area of ​​the casting module via a transverse transport mechanism, enabling efficient movement of the mobile pedestal 1 through the "casting-steaming-demolding-recycling" process.

[0088] During actual production, after mobile pedestal 1 completes the entire process carrying the beam (i.e., the beam is transported to beam storage area 57), it is returned via the transmission line and received by the first transverse shuttle module, where it is repositioned for reuse by the casting module. Mobile pedestal 1 and bottom mold 3 are then reassembled with side molds 4 for mold closing. This entire process requires no manual intervention or extended waiting time, eliminating resource waste caused by poor station connections on the production line. This ensures that the casting module continuously has access to a usable mobile pedestal 1, ensuring a consistent production rhythm.

[0089] The layout of the first transverse ferry module can form a compact space coordination with the casting module and the steaming module, realize the uninterrupted transportation of the mobile platform 1 through the standardized rail interface, optimize the plane layout of the production line, reduce the ineffective distance between equipment, and further improve the site utilization efficiency and production automation level.

[0090] According to one embodiment of the present application, the first transverse ferry module is arranged upstream of the casting module, and the first transverse ferry module transports the mobile platform 1 to the casting module. Figure 9 Alternatively, the first transverse ferry module and the pouring module are arranged at the same station, as shown in FIG. Figure 10 shown.

[0091] The first transverse ferry module in the beam production system can be arranged in two ways: it can be set upstream of the casting module or at the same workstation as the casting module, forming a differentiated and efficient connection solution for the recovery and supply of the mobile platform 1.

[0092] When the first transverse shuttle module is located upstream of the casting module, the used mobile pedestal 1 is pre-delivered to the waiting area in front of the casting module via a pre-set track or transmission mechanism. This allows the casting module to access the available mobile pedestal 1 before the mold closing process, avoiding production stagnation caused by delayed transportation of the mobile pedestal 1, effectively shortening process waiting time and improving the continuous operation capacity of the casting module. This layout is suitable for assembly line production planning, and the spatial separation of upstream and downstream stations enables process-based control of the flow of the mobile pedestal 1.

[0093] When the first transverse shuttle module and the pouring module are located in the same workstation, the integrated design embeds the recycling and supply functions of the mobile pedestal 1 into the pouring area. This allows the mobile pedestal 1 to be directly transferred to the pouring preparation state after use. This eliminates the lateral transportation distance of the mobile pedestal 1 between different workstations, maximizes space occupancy, and improves the integration of workstations. This layout significantly reduces the longitudinal length of the production line and is suitable for compact production layouts in space-constrained environments. By recycling the mobile pedestal 1 within the same area, a multifunctional "demolding-recycling-assembly" system is formed, further enhancing the efficiency and space utilization of the production process.

[0094] According to one embodiment of the present application, Figure 9 and Figure 10 As shown, the beam production system also includes a second transverse ferry module, which is arranged downstream of the steaming module. The second transverse ferry module is configured to move the mobile base 1 after use horizontally to the conveying line returning to the casting module, and transport it to the first transverse ferry module through the conveying line.

[0095] The second transverse ferry module, located downstream of the steaming module, is installed in the beam production system. It moves the mobile pedestal 1 after steaming to the conveyor line that returns to the casting module, forming a closed-loop flow channel for the mobile pedestal 1 in the "casting-steaming-recycling" process. The second transverse ferry module connects to the downstream outlet of the steaming module. After the beam completes final curing and is released from the mobile pedestal 1, it promptly receives the unloaded mobile pedestal 1 and transfers it laterally to the designated conveyor line. This allows the mobile pedestal 1 to return to the casting module for the next round of production without detours or waiting, significantly reducing the mobile pedestal's non-productive time and improving its turnover efficiency.

[0096] The second transverse shuttle module realizes uninterrupted transmission of the mobile platform 1 through a standardized rail interface or a translation mechanism, avoiding the waste of resources of the mobile platform 1 due to manual scheduling or circuitous routes in traditional processes, ensuring the time connection accuracy of each link of the production line, and effectively enhancing the automation continuity of the production process. It is especially suitable for large-scale production scenarios where multiple mobile platforms 1 operate in parallel, while improving equipment utilization and reducing operational risks caused by manual intervention.

[0097] The second transverse ferry module forms upstream and downstream collaboration with the upstream first transverse ferry module, which are respectively responsible for the recovery and supply of the pedestal, and jointly build a two-way efficient transportation network for the mobile pedestal 1, further optimizing the logistics balance of the production line.

[0098] According to one embodiment of the present application, Figure 9 and Figure 10 As shown, the beam production system includes multiple production lines 61 and at least one return line 62. The mobile platform 1 cooperates with the production lines 61 to enable the mobile platform 1 to drive the beam to complete the production process. The mobile platform 1 cooperates with the return line 62 to return the mobile platform 1 to the casting module via the return line 62 after use. There can be four production lines 61.

[0099] The beam production system utilizes a combination of multiple production lines 61 and at least one return line 62, creating a bidirectional, efficient flow system for the mobile pedestal 1 during the production process. Multiple production lines 61 can simultaneously carry multiple mobile pedestals 1 to complete processes such as mold closing, casting, demolding, steaming, and storage in parallel, thereby increasing the production line's production capacity per unit time. As the mobile pedestal 1 passes through each workstation on the production line 61, it can independently control its flow rhythm based on beam specifications or process requirements, avoiding overall production stoppages due to process debugging or equipment maintenance on a single line and enhancing the stability and flexibility of the system's operation. The return line 62 is specifically designed to carry an empty mobile pedestal 1 that has completed the entire production process, allowing it to return directly to the casting module along an independent path, forming a closed "production-return" loop with the production line 61. This eliminates ineffective turns or cross-interference between workstations for the mobile pedestal 1 and ensures a clear and orderly logistics path. This layout design not only ensures the continuity of the beam production process by physically separating the production line 61 from the return line 62, but also improves the turnover efficiency of the mobile platform 1, effectively reduces the waiting time of the mobile platform 1, and reduces the equipment idle rate.

[0100] In actual applications, the production line 61 and the return line 62 can be upgraded to be intelligent. For example, a dynamic scheduling system can be added to monitor the pedestal position and process progress of each workstation in real time through sensors, automatically assign the use priority of the return line 62, and achieve load balancing among multiple lines.

[0101] According to a beam production method of the fourth embodiment of the present application, Figure 15 As shown, the beam production method uses the aforementioned beam production system, including: pouring concrete into the formwork assembly; transporting the beam to the steaming curing area for steaming curing; demolding the steamed beam; transporting the beam to the steaming curing area for steaming curing again; and tensioning the beam once.

[0102] The formwork assembly here refers to the bottom formwork 3 and side formwork 4 in the aforementioned formwork system, and does not include devices such as the movable base 1 and fixed base 2 in the formwork system; of course, in some cases, the formwork assembly may further include end formwork and wing plate formwork.

[0103] The beam production method relies on a supporting beam production system, organically linking the pouring, steaming, demolding, and tensioning processes to form an efficient and coordinated production process. During the concrete pouring phase, the side forms 4 of the formwork assembly can be moved along the track to enclose the bottom form 3, quickly constructing a closed pouring cavity, improving mold closing efficiency and ensuring the dimensional accuracy of the beam. During the steaming phase after demolding, the beam is transported to the steaming area. Since the side forms 4 have been separated from the movable pedestal 1 after demolding, the subsequent partial steaming area only needs to accommodate the compact structure of "movable pedestal 1 + bottom form 3 + beam body". Compared with traditional processes, this reduces the redundant space caused by formwork space occupation, reduces steam consumption, and shortens curing time.

[0104] According to one embodiment of the present application, demolding the steam-cured beam body includes: transporting the steam-cured beam body to the casting area 52 for demolding.

[0105] The demoulding process is completed in the pouring area 52. The detachable design of the template assembly is used to quickly separate the side form 4 from the movable base 1, avoiding the heavy side form 4 from being transferred to other workstations with the movable base 1 after demoulding, reducing ineffective transportation and equipment load between processes, and improving the efficiency of workstation connection.

[0106] The beam production method returns the steam-cured beam to the casting area 52 for demolding, creating a closed-loop process of "casting - steaming - demolding - re-steaming - tensioning." This breaks the traditional, lengthy, multi-station workflow, reduces the frequent movement of the mobile platform 1 between different stations, shortens the production cycle, and reduces equipment wear. Furthermore, the coordinated design of the formwork assembly and the steaming area optimizes the use of the steaming space and controls energy costs while ensuring beam curing quality. This provides a highly efficient, energy-efficient, and quality-controlled technical solution for the industrialized production of rail beams.

[0107] According to one embodiment of the present application, the beam is transported to the steam curing area for steam curing, which includes: the mobile base 1 carries the cast beam and formwork assembly to the steam curing area, and steam cures the beam for the first time.

[0108] In the beam production method, the mobile pedestal 1 carries the cast beam and formwork assembly to the steaming and curing area for the first steaming process, which forms a key process link for the early strength development of the beam. In this process, the mobile pedestal 1 acts as a carrier to transport the formwork assembly and the beam as a whole to the steaming and curing area, so that the beam is subject to temperature and humidity control under the protection of the formwork, ensuring that the hydration reaction of the concrete in the initial setting stage is in a stable environment. The side formwork 4 and the bottom formwork 3 of the formwork assembly remain in a closed mold state at this time, providing precise shape constraints for the beam, avoiding dimensional deviations caused by plastic deformation of concrete during the steaming process, and ensuring the molding accuracy of the component. The core goal of the first steaming is to make the beam reach the demoulding strength. The integrity of the formwork assembly in this process ensures structural stability during the steaming process, preventing the side formwork 4 from shifting or the bottom formwork 3 from deforming and causing damage to the beam.

[0109] Mobile pedestal 1 directly carries the formwork components and beam body into the steam-curing area, achieving a seamless connection between the pouring and steam-curing processes. At the same time, although the formwork components occupy a certain amount of space during the first steam-curing, combined with the separation design of the side formwork 4 and mobile pedestal 1 in the subsequent demolding process, a closed process loop of "curing with formwork - demolding - fine curing without formwork" is formed. The first steam-curing focuses on building a strength foundation under the constraints of the formwork, and the subsequent steam-curing can adopt a more compact spatial layout due to the detachment of the formwork, thereby reducing energy consumption in the steam-curing process as a whole. Through the integrated transportation of mobile pedestal 1 and the phased role of the formwork components, this process not only ensures the early curing quality of the beam body, but also creates conditions for efficiency optimization and cost control in subsequent processes, improving the continuity of the production process and process reliability.

[0110] According to one embodiment of the present application, the steam-cured beam body is transported to the casting area 52 for demolding, including: the mobile base 1 carries the beam body and the formwork assembly after the first steaming to the casting area 52 for demolding, and leaves the side formwork 4 in the formwork assembly in the casting area 52, and the bottom formwork 3 continues to move with the mobile base 1.

[0111] In the beam production method, the mobile base 1 carries the beam and the formwork assembly after the first steaming to the casting area 52 for demolding, and leaves the side form 4 in the formwork assembly in the casting area 52, and the bottom form 3 continues to move with the mobile base 1, forming an efficient separation mechanism between the formwork assembly and the mobile base 1.

[0112] Mobile pedestal 1 transports the entire "beam body + formwork assembly" after the initial steaming process back to casting area 52. The side forms 4, through the coordinated structure between the rails (e.g., the switching between first rail 11 and second rail 23), are separated from mobile pedestal 1 during demolding and retained at a designated location in casting area 52. However, bottom form 3, being fixed to mobile pedestal 1, can continue to move with it. The side forms 4, as detachable components, remain in casting area 52 for the next mold closing, avoiding their movement with mobile pedestal 1 to subsequent workstations. This significantly reduces the load-bearing capacity of mobile pedestal 1 and minimizes its space requirements, facilitating the compactness of subsequent processes.

[0113] After demolding, the bottom form 3 continues to move with the mobile pedestal 1, ensuring the continuity of the bottom form 3 and the mobile pedestal 1. This allows for the next production cycle without requiring additional disassembly and assembly, improving pedestal reuse efficiency. The side form 4 remains in the casting area 52 and quickly reassembles with the returning mobile pedestal 1 and bottom form 3 to form a new casting cavity. This reduces the time and manual labor associated with transporting the formwork across workstations, creating a highly efficient "demolding-retention-reassembly" cycle. Furthermore, since the side form 4 no longer follows the mobile pedestal 1 into subsequent steaming or tensioning stations, the equipment dimensions for subsequent processes (such as the second steaming chamber) can be precisely designed based on the actual specifications of the "mobile pedestal 1 + bottom form 3 + beam body." This reduces redundant space caused by formwork placement, steam consumption, and equipment investment costs. The dynamic separation of the formwork components and the continuous rotation of the pedestal effectively improve the continuity of the production process and equipment utilization. While ensuring beam demolding accuracy, it also lays the foundation for energy-saving optimization and efficiency improvements in the overall process.

[0114] According to one embodiment of the present application, demolding the steam-cured beam body includes: demolding the steam-cured beam body in the steam-curing area.

[0115] After steaming with the mold, the beam body is synchronously in the steaming area with the movable base 1 and the fixed base 2. At this time, the side mold 4 can be separated from the bottom mold 3 along the second track of the fixed base 2. The fixed base 2 drives the side mold 4 to return to the casting area 52 independently through the running wheels at the bottom. The movable base 1 carries the bottom mold 3 and the beam body directly into the subsequent steaming, tensioning and other processes without returning to the casting area 52 for demoulding. In-situ demolding in the steaming and curing zone eliminates the need for mobile pedestal 1 to transport the beam back and forth to casting zone 52, further shortening production cycles and reducing transportation energy consumption. After demolding, the side molds 4 can be returned to casting zone 52 along with the fixed base 2 to await the next mold closing and casting operation, while mobile pedestal 1 focuses on continuous transport of the beam for subsequent processing steps. Demolding in the steaming and curing zone avoids potential surface damage to the beam during cross-zone transportation, simplifies the workstation connection process, supports the compact layout and high-speed operation of the automated production line, and effectively improves the overall efficiency and process reliability of rail beam production.

[0116] According to one embodiment of the present application, the beam is transported to the steaming curing area for steaming curing, including: the mobile base 1 and the fixed base 2 carry the cast beam and the formwork assembly to the steaming curing area, and steam-curing the beam for the first time.

[0117] The movable pedestal 1 and the fixed pedestal 2 carry the cast beam and formwork assembly to the steaming curing area for the first steaming curing. In this process, the movable pedestal 1 carries the fixed bottom formwork 3, and the fixed pedestal 2 moves synchronously with the movable pedestal 1 through the bottom running wheels. The movable pedestal 1 and the fixed pedestal 2 share the weight of the formwork assembly, avoiding the weight of the formwork assembly being borne entirely by the movable pedestal 1, and avoiding the situation where the movable pedestal 1 is easily damaged.

[0118] The formwork assembly is transported integrally with the mobile pedestal 1 and fixed pedestal 2, allowing the beam to enter the steam curing area directly after pouring without disassembling the formwork. During the first steam curing, the formwork assembly provides precise shape constraints for the beam, ensuring a stable environment for the concrete's hydration reaction during the initial setting phase, effectively promoting early strength development and preventing plastic deformation.

[0119] According to one embodiment of the present application, the steam-cured beam body is demolded in the steam-curing area, including: after the movable base 1 and the fixed base 2 carry the cast beam body and the formwork assembly to complete steaming in the steam-curing area, the fixed base 2 carries the side formwork 4 in the formwork assembly back to the casting area 52, and the bottom formwork 3 continues to move with the movable base 1.

[0120] After steaming and curing to reach the demoulding strength, the fixed base 2 is separated from the movable base 1 through the bottom running wheel, and carries the side form 4 back to the casting area 52. Since the bottom form 3 is fixed to the movable base 1, it can directly enter the subsequent steaming, tensioning and other processes with the movable base 1. The movable base 1 does not need to carry the beam body back to the casting area 52 for demoulding, thereby shortening the time required for beam body manufacturing.

[0121] In-situ demolding in the steam curing area eliminates the need for round-trip transport of the mobile pedestal 1, further shortening production cycles and reducing equipment energy consumption. The independent return mechanisms of the fixed base 2 and side forms 4 allow the formwork assembly to complete mold closing preparations in advance in the casting area 52, enabling parallel operation with the subsequent movement of the mobile pedestal 1 and improving formwork turnover efficiency.

[0122] According to one embodiment of the present application, before pouring concrete into the formwork assembly, the process further includes: closing the mold in the pouring area 52 .

[0123] The movable pedestal 1 carries the fixed bottom form 3 and is positioned in the casting area 52. The side forms 4 on both sides are moved from the second track 23 on the fixed base 2 to the first track 11 of the movable pedestal 1 through the cooperation structure with the first track 11 and the second track 23, and are surrounded by the bottom form 3 to form a closed cavity for casting the beam body. This mold closing method realizes the rapid positioning and docking of the side forms 4 through track guidance and mechanical cooperation, shortens the mold closing time and reduces manual intervention, and improves the efficiency of the production preparation stage. The precise alignment of the side forms 4 and the bottom form 3 under the guidance of the track system can effectively ensure the dimensional accuracy and sealing performance of the casting cavity, avoid leakage or deformation during the concrete pouring process, and ensure that the external dimensions of the beam body meet the design requirements from the source.

[0124] The design of centralized mold closing operations in pouring area 52 allows for the assembly of formwork components and concrete pouring to be completed in the same area, creating a compact "mold closing-pouring-transportation" process and reducing the time and mechanical losses associated with transporting formwork components across different areas. The movable pedestal 1, the core support for the mold closing process, maintains structural stability during mold closing through its fixed connection to the base form 3 and its movable connection to the side forms 4. This allows for the subsequent separation and retention of the side forms 4 during demolding, enabling the efficient "combination use-separation turnover" cycle of formwork components.

[0125] In practical applications, an automated detection step can be introduced into the mold closing process. The docking accuracy of the side mold 4 and the bottom mold 3 can be monitored in real time through a laser ranging or visual recognition system. The linkage control system can automatically adjust the position of the side mold 4 to further improve the consistency of the mold closing quality.

[0126] During the mold closing process, a sealing adjustment step can also be introduced, such as setting an elastic sealing component on the contact surface of the side mold 4 and the bottom mold 3, and dynamically adjusting the sealing pressure through air pressure or hydraulic devices to adapt to the anti-leakage requirements under different casting conditions.

[0127] According to one embodiment of the present application, before the casting area 52 is molded, the process further includes: moving the platform 1 back to the first transverse ferry area 51 and adjusting the position to the position to be molded.

[0128] In the beam production method, before the mold is closed in the casting area 52, the mobile base 1 is returned to the first transverse ferry area 51 and adjusted to the position to be closed, forming a key preparatory link for the precise flow and positioning of the mobile base 1 in the production process. In this step, the mobile base 1 that has completed the previous round of production process returns to the designated area near the casting area 52 through the first transverse ferry area 51, and accurately adjusts its own position through the transverse ferry vehicle in the first transverse ferry area 51, so that the bottom mold 3 and the closing station of the casting area 52 are aligned in coordinates, creating conditions for the subsequent rapid docking of the side mold 4 and the bottom mold 3. Through the transfer and position calibration of the first transverse ferry area 51, it is ensured that the mobile base 1 enters the closing process in a standard posture, avoiding the docking misalignment of the side mold 4 or the casting cavity size error caused by the position deviation of the mobile base 1, and ensuring the beam forming accuracy from the source.

[0129] The position adjustment process of the mobile pedestal 1 in the first transverse ferry area 51 can be carried out simultaneously with the preparation of the side mold 4 of the template assembly, that is, when the mobile pedestal 1 is positioned, the side mold 4 is already on standby on the second track 23, forming a parallel working mode of "pedestal return-side mold 4 movement-quick mold closing", which significantly shortens the production preparation time. This step improves the orderliness and safety of the workstation connection by integrating the flow and position calibration of the mobile pedestal 1 in the ferry area. In addition, the standardized design of the position to be closed facilitates the automated control of the production line. The coordinate parameters can be preset through the control system, so that the adjustment process of the mobile pedestal 1 does not require manual intervention, thereby enhancing the intelligence of the production process.

[0130] According to one embodiment of the present application, the first transverse ferry area 51 is located upstream of the casting area 52; the mobile platform 1 returns to the first transverse ferry area 51 and adjusts its position to the position to be molded, including: the mobile platform 1 returns to the first transverse ferry area 51, and moves horizontally in the first transverse ferry area 51 to the position corresponding to the production line 61 of the casting area 52, and transports the mobile platform 1 from the first transverse ferry area 51 to the casting area 52.

[0131] The first transverse ferry area 51 is located upstream of the casting area 52. The mobile pedestal 1 returns to this area and moves horizontally there to a position corresponding to the production line 61 of the casting area 52 before being transported to the casting area 52. This forms a key mechanism for the orderly flow and precise docking of the mobile pedestal 1 within the production process. In this process, after completing the previous steps, the mobile pedestal 1 first returns to the upstream first transverse ferry area 51. The transverse mechanism of the first transverse ferry area 51 adjusts its horizontal position so that the centerline of the bottom mold 3 on the pedestal aligns with the mold closing station coordinates of the production line 61 of the casting area 52. The mobile pedestal 1 is then smoothly transported to the casting area 52 by the transport device of the first transverse ferry area 51. Because the mobile pedestal 1 in the first transverse ferry area 51 and the second transverse ferry area 56 only carries the bottom mold 3 (without the side mold 4 and its related supporting mechanisms), its weight is significantly reduced, allowing it to be transported using a conventional shuttle bus or gantry crane, eliminating the need for a dedicated transverse ferry bus for transverse movement and track switching.

[0132] Through the pre-positioning function of the upstream first transverse ferry area 51, the position calibration and posture adjustment of the mobile platform 1 are completed in advance, avoiding secondary adjustments or docking errors caused by position deviation after the platform directly enters the casting area 52, and significantly improving the preparation efficiency and accuracy of the mold closing process.

[0133] The first transverse ferry area 51 serves as a pre-buffer area for the casting area 52. It can simultaneously receive the mobile pedestals 1 returned from multiple production lines 61. Through translational scheduling, the pedestals enter the casting area 52 in sequence according to the production plan, forming a streamlined preparation process of "pedestal recovery-position calibration-ordered supply". This effectively avoids the congestion and waiting of multiple mobile pedestals 1 at the entrance of the casting area 52, so that the casting area 52 is always in a ready state for mold closing, ensuring the continuous progress of the concrete pouring process. In addition, the corresponding position design of the first transverse ferry area 51 and the production line 61 of the casting area 52 realizes seamless connection of pedestal transportation through standardized interfaces, reduces the risk of mechanical collision caused by differences in workstation coordinates, and improves the safety and stability of production line operation.

[0134] In actual applications, an intelligent scheduling system can be integrated in the first transverse ferry area 51 to monitor the position information of each mobile pedestal 1 and the status of the workstation in the casting area 52 in real time through the sensor network, and automatically allocate the ferry path and docking sequence based on the production scheduling algorithm to achieve dynamic optimization of the pedestal flow.

[0135] According to one embodiment of the present application, the first transverse ferry area 51 and the casting area 52 are arranged at the same workstation; the mobile platform 1 returns to the first transverse ferry area 51 and adjusts its position to the position to be molded, including: the mobile platform 1 returns to the first transverse ferry area 51 and moves horizontally in the first transverse ferry area 51 to the corresponding position of the production line 61.

[0136] The first transverse ferry area 51 and the casting area 52 are located at the same workstation. The mobile platform 1 returns to this area and moves horizontally to the corresponding position of the production line 61, forming a compact production model with efficient circulation and precise positioning of the mobile platform 1 within a single workstation. In this process, the mobile platform 1, having completed the previous process, returns directly to the first transverse ferry area 51, which is co-located with the casting area 52. The position is adjusted through the transverse mechanism or rail system within the area, so that the coordinates of the bottom mold 3 on the mobile platform 1 are aligned with the production line 61 of the mold closing station in the casting area 52, and the mold closing preparation state can be entered without cross-station transportation.

[0137] By integrating workstations, the round-trip transportation time of the mobile base 1 between different areas is reduced, and the recovery, position adjustment and mold preparation of the mobile base 1 are concentrated in the same space, which significantly improves the workstation utilization efficiency and the consistency of production rhythm.

[0138] The co-location of the first transverse ferry area 51 and the casting area 52 allows the mobile pedestal 1 to immediately enter the first transverse ferry area 51 for fine-tuning after use. Formwork components such as the side molds 4 can be kept on standby in the surrounding area, creating an immediate response mechanism: "mobile pedestal 1 returns to its original position - side molds 4 dock - rapid mold closing." This avoids the need for the mobile pedestal 1 to wait or take circuitous routes due to separate workstations. The integrated operation within the same workstation facilitates unified control by the automated system. Pre-set workstation coordinate parameters and mechanical positioning devices enable unmanned position adjustment of the mobile pedestal 1, reducing human intervention errors and enhancing the stability of the production process.

[0139] In actual applications, an intelligent linkage device can be set at the first transverse ferry area 51 and the casting area 52 of the same workstation. Through real-time interaction between the pressure sensor installed at the bottom of the movable pedestal 1 and the laser centering system of the mold closing station, high-precision calibration of the position of the movable pedestal 1 can be automatically completed to meet the strict requirements of high-precision rail beam production on mold closing positioning.

[0140] According to an embodiment of the present application, the steaming area includes a first steaming area 53 and a second steaming area 54; transporting the beam to the steaming area for steaming again includes: transporting the beam to the second steaming area 54 for steaming a second time.

[0141] After demoulding, the beam body directly enters the second steaming zone 54 for a second steaming; at this time, the first steaming zone 53 is idle, and the pouring zone 52 continues to pour the next beam body. After pouring, it enters the first steaming zone 53 for steaming to reach the demoulding strength.

[0142] A second steaming step is implemented when the beam is transported to the steaming curing area for further steaming, forming a phased, refined curing process. In this process, after the first steaming curing and demolding of the beam, the mobile platform 1 carries it to the second steaming curing area 54 for a second steaming curing. Because the first steaming curing area 53 needs to accommodate the beam for the first steaming curing (i.e., steaming with the beam in the formwork), it can be designed to a conventional size. Once in the second steaming curing area 54, the beam is freed from the constraints of the side formwork 4. The second steaming curing area 54 can precisely plan its interior space based on the actual contours of the "mobile platform 1 + bottom formwork 3 + beam," focusing on promoting rapid concrete strength growth through moderate temperature control.

[0143] The functional subdivision of the two curing zones closely matches the requirements of the different stages of the concrete hydration reaction. The second curing zone, leveraging the space available after demolding without the side forms 4, accelerates the hydration of the cementitious material at a relatively high temperature, shortening the time it takes to build strength. Alternatively, by slowly cooling the temperature and maintaining moisture retention, the system ensures that the internal moisture of the beam is fully engaged in the reaction, reduces thermal stresses, and enhances component density and crack resistance. Furthermore, since the second curing zone 54 does not require formwork components, its design can be optimized based on the actual specifications of the beam and the movable platform 1. This significantly reduces redundant space compared to traditional curing rooms, significantly reducing steam consumption and energy costs. This process, through the orderly movement of the movable platform 1 between curing zones, achieves gradient control of the curing process and efficient utilization of equipment resources, ensuring consistent quality control of the beam from initial to final setting, effectively improving the reliability and cost-effectiveness of rail beam production.

[0144] According to one embodiment of the present application, the steaming area includes a first steaming area 53, a second steaming area 54 and a third steaming area 55; transporting the beam to the steaming area for steaming again includes: transporting the beam to the second steaming area 54 for steaming for the second time; and transporting the beam to the third steaming area 55 for steaming for the third time.

[0145] The steaming zone in the beam body production method can be set corresponding to the steaming chamber in the beam body production system, for example: the first steaming chamber can be specifically adopted in the first steaming zone 53 to steam-cure the beam body; the second steaming zone 54 can be specifically adopted in the form of a second steaming chamber; and the third steaming zone 55 can be specifically adopted in the form of a third steaming chamber.

[0146] In addition to the first and second steam curing zones 53 and 54, a third steam curing zone 55 can be further provided. The beam enters the third steam curing zone 55 for a third steam curing. The low-temperature, moisturizing environment controls the beam's cooling rate and reduces shrinkage stress, ensuring final strength and internal structural stability.

[0147] More steaming and curing areas can more precisely control the curing process and effectively improve the final forming quality of the beam.

[0148] According to one embodiment of the present application, the beam body is tensioned once, including: after the beam body reaches the tensioning strength, the beam body is transported to the second transverse ferry area 56, and the beam body is tensioned once.

[0149] After the multi-stage fine curing in the first steam curing zone 53, the second steam curing zone 54 and the third steam curing zone 55, the concrete strength of the beam has been uniformly increased through gradient temperature and humidity control and has met the design requirements. At this time, the prestressing conditions can be met without the need for secondary or multiple tensioning in traditional processes.

[0150] The second transverse ferry area 56 serves as a tensioning station. Its layout can closely connect the steaming area and subsequent processes, so that the beam body can be directly transported to the second transverse ferry area 56 after completing the final steaming. With the help of the positioning device of the second transverse ferry area 56, the axis of the beam body and the tensioning equipment are accurately aligned, avoiding the tensioning position error caused by cross-zone transportation deviation, and ensuring the directional accuracy of prestressing and the uniformity of force.

[0151] In the embodiment of the present application, by optimizing the production process and the arrangement sequence of each workstation, the steaming time of the beam in the steaming area is greatly extended, so that the beam does not need to rely on multiple tensioning to compensate for strength differences after demolding, which significantly reduces the time consumption and equipment loss of the tensioning process.

[0152] The second transverse ferry area 56 can also be integrated with a tensioning stress monitoring system to collect beam strain data in real time during the tensioning process, and the linkage control system adjusts the tensioning force value to achieve intelligent control of prestressing and further improve the stability of the mechanical properties of the component.

[0153] According to one embodiment of the present application, after the beam body is tensioned once, it also includes: the beam body is transported to the beam storage area 57 through the second transverse ferry area 56; the mobile platform 1 is translated to the return conveying line through the second transverse ferry area 56, and returns to the casting area 52.

[0154] The tensioned beams are smoothly transferred to the designated location in the beam storage area 57 via the directional transport mechanism of the second transverse ferry area 56, avoiding the risk of component damage caused by manual lifting or cross-area transportation, and ensuring the appearance quality and structural integrity of the beams. After unloading the beams, the mobile pedestal 1 directly enters the return conveyor line via the translation track of the second transverse ferry area 56, returning to the casting area 52 to participate in the next round of mold closing without detours or waiting, significantly reducing the pedestal's non-productive time and improving its turnover efficiency.

[0155] The second transverse ferry area 56 serves as a key hub at the end of the production process. Its layout closely connects the tensioning station, the beam storage area 57 and the return line 62, so that the beam transfer and the recovery of the mobile pedestal 1 are completed simultaneously in the same area, forming an efficient connection mechanism of "tensioning-transfer-recovery", effectively avoiding the waste of resources caused by the circuitous transfer route or the delayed scheduling of the mobile pedestal 1 in traditional processes, ensuring the time connection accuracy of each link of the production line, and is particularly suitable for large-scale production scenarios with multiple pedestals operating in parallel.

[0156] The beam production method provided in the embodiments of the present application can be exemplarily performed according to the following steps: The mobile platform 1 returns to the first transverse ferry area 51 and is transported to the casting area 52 by the first transverse ferry area 51, or the first transverse ferry area 51 and the casting area 52 are set at the same station, and the mobile platform 1 adjusts its position to the position to be molded; Perform mold closing in the casting area 52; pouring concrete into the cavity formed by the formwork assembly at the pouring area 52; The formed beam body is transported with the mold to the steam curing area for the first steam curing; The beam body after the first steam curing is transported to the casting area 52 for demoulding; the side mold 4 remains in the casting area 52, and the bottom mold 3 continues to move with the movable base 1; The movable base 1 transports the demoulded beam to the steam curing area for steam curing again, including the second steam curing and the third steam curing; Transporting the beam to the second transverse ferry area 56 for tensioning; The beam body is transported to the beam storage area 57, and the movable platform 1 with the bottom form 3 is returned to the casting area 52; the cycle is repeated.

[0157] Finally, it should be noted that the above embodiments are intended only to illustrate the present application and are not intended to limit the present application. Although the present application has been described in detail with reference to the embodiments, those skilled in the art will appreciate that various combinations, modifications, or equivalent substitutions of the technical solutions of the present application do not depart from the spirit and scope of the technical solutions of the present application and are intended to be encompassed by the claims of the present application.

Claims

1. A template system, characterized in that: include: A movable platform (1) is provided with a first track (11); A fixed seat (2) is arranged on both sides of the movable platform (1), and a second track (23) is provided on the fixed seat (2); A bottom mold (3) is fixed on the movable base (1), and the first rails (11) are located on both sides of the bottom mold (3); The side form (4) can be moved from one of the first track (11) and the second track (23) to the other. When the side form (4) moves to the first track (11), the side form (4) and the bottom form (3) enclose and form a cavity for casting the beam body.

2. The formwork system according to claim 1, characterized in that It also includes a pushing mechanism (24) arranged on the fixing seat (2), and the pushing mechanism (24) is configured to drive the side mold (4) to move between the first track (11) and the second track (23).

3. The formwork system according to claim 1, characterized in that A slider (41) is provided at the bottom of the side mold (4) and cooperates with the first track (11) and the second track (23).

4. A template system, characterized in that: include: Mobile pedestal (1); A fixed seat (2) is provided on both sides of the movable seat (1), and a second track (23) is provided on the fixed seat (2); a running wheel is provided at the bottom of the fixed seat (2), so that the fixed seat (2) can move with the movable seat (1); A bottom mold (3) is fixed on the movable base (1); The side formwork (4) is movably mounted on the second track (23); when the side formwork (4) approaches the bottom formwork (3) along the second track (23), the side formwork (4) and the bottom formwork (3) enclose and form a cavity for casting the beam body.

5. A beam production system, characterized in that: include: A casting module, comprising the formwork system according to any one of claims 1 to 3 or the formwork system according to claim 4, wherein the casting module is used for closing the mold and casting the beam body; a steaming module, configured to steam-cure the beam body cast by the casting module; One of the casting module and the steaming module is further configured to demould the beam body after being steamed in the steaming module.

6. The beam production system according to claim 5, characterized in that: The steaming module comprises: a first steaming curing chamber configured to steam-cure the beam body cast by the casting module; the casting module is configured to demould the beam body after steaming in the first steaming curing chamber, or the beam body is demoulded in the first steaming curing chamber after steaming in the first steaming curing chamber; The second steaming chamber is configured to steam-cure the beam body that has been steamed in the first steaming chamber again.

7. The beam production system according to claim 5, characterized in that: It also includes a first transverse ferry module, which is configured to receive a mobile pedestal (1) that is recycled after use and is used by the casting module.

8. The beam production system according to claim 7, characterized in that: The first transverse ferry module is arranged upstream of the casting module, and the first transverse ferry module transports the movable platform (1) to the casting module; or, The first transverse ferry module and the pouring module are arranged at the same workstation.

9. The beam production system according to claim 5, characterized in that: It also includes a second transverse ferry module, which is arranged downstream of the steaming module and is configured to horizontally move the mobile platform (1) after use to a conveying line returning to the casting module.

10. The beam production system according to claim 5, characterized in that: The beam production system includes a plurality of production lines (61) and at least one return line (62); The movable platform (1) cooperates with the production line (61) so that the movable platform (1) drives the beam body to complete the production process; the movable platform (1) cooperates with the return line (62) so that the movable platform (1) returns to the casting module via the return line (62) after use.

11. A beam production method, characterized in that: The beam production system according to any one of claims 5 to 10 comprises: pouring concrete into the formwork assembly; Transport the beam to the steam curing area for steam curing; Demoulding the beam after steam curing; Transport the beam to the steam curing area for steam curing again; The beam is tensioned once.

12. The beam production method according to claim 11, characterized in that: Demolding the steam-cured beam body includes: The steam-cured beam body is transported to the casting area (52) for demoulding.

13. The beam production method according to claim 12, characterized in that: The method of transporting the beam to the steaming area for steaming includes: The mobile pedestal (1) carries the cast beam body and the formwork assembly to the steam curing area, and performs the first steam curing on the beam body.

14. The beam production method according to claim 13, characterized in that: The steam-cured beam body is transported to the casting area (52) for demoulding, comprising: The movable pedestal (1) carries the beam body and the formwork assembly after the first steaming to the casting area (52) for demoulding, and leaves the side formwork (4) in the formwork assembly in the casting area (52), and the bottom formwork (3) continues to move with the movable pedestal (1).

15. The beam production method according to claim 11, characterized in that: Demolding the steam-cured beam body includes: The steam-cured beam is demoulded in the steam-curing area.

16. The beam production method according to claim 15, characterized in that: The method of transporting the beam to the steaming area for steaming includes: The movable base (1) and the fixed base (2) carry the cast beam body and the formwork assembly to the steam curing area, and perform the first steam curing on the beam body.

17. The beam production method according to claim 16, characterized in that: Demolding the steam-cured beam in the steam-curing area includes: After the movable pedestal (1) and the fixed pedestal (2) carry the cast beam and formwork assembly to complete steam curing in the steam curing area, the fixed pedestal (2) carries the side formwork (4) in the formwork assembly back to the casting area (52), and the bottom formwork (3) continues to move with the movable pedestal (1).

18. The beam production method according to any one of claims 11 to 17, characterized in that: Before pouring concrete into the formwork assembly, the method further comprises: The mold is closed in the casting area (52).

19. The beam production method according to claim 18, characterized in that: Before the mold is closed in the casting area (52), the method further includes: The movable base (1) returns to the first transverse ferry area (51) and adjusts its position to the position to be molded.

20. The beam production method according to claim 19, characterized in that: The first transverse ferry area (51) is located upstream of the pouring area (52); The movable platform (1) returns to the first transverse ferry area (51) and adjusts its position to the position to be molded, including: The movable platform (1) returns to the first transverse ferry area (51), and is translated in the first transverse ferry area (51) to a position corresponding to the production line (61) of the casting area (52), so as to transport the movable platform (1) from the first transverse ferry area (51) to the casting area (52).

21. The beam production method according to claim 19, characterized in that: The first transverse ferry area (51) and the pouring area (52) are arranged at the same workstation; The movable platform (1) returns to the first transverse ferry area (51) and adjusts its position to the position to be molded, including: The movable platform (1) returns to the first transverse ferry area (51), and moves horizontally in the first transverse ferry area (51) to a corresponding position of the production line (61).

22. The beam production method according to any one of claims 11 to 17, characterized in that: The steaming curing area includes a first steaming curing area (53) and a second steaming curing area (54); The method of transporting the beam to the steaming area for re-steaming includes: The beam body is transported to the second steaming area (54) for a second steaming.

23. The beam production method according to any one of claims 11 to 17, characterized in that: The steam curing area includes a first steam curing area (53), a second steam curing area (54) and a third steam curing area (55); The method of transporting the beam to the steaming area for re-steaming includes: Transporting the beam to the second steaming area (54) for a second steaming; The beam body is transported to the third steaming curing area (55) for the third steaming curing.

24. The beam production method according to any one of claims 11 to 17, characterized in that: The method of performing a tensioning operation on the beam body comprises: After the beam reaches the tensioning strength, the beam is transported to the second transverse ferry area (56) and tensioned once.

25. The beam production method according to any one of claims 11 to 17, characterized in that: After the beam body is tensioned once, the method further includes: The beam body is transported to the beam storage area (57) via the second transverse ferry area (56); the mobile pedestal (1) is horizontally moved to the return conveying line via the second transverse ferry area (56) and returns to the casting area (52).

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