Tensioning force control device for prestressed sleepers

Abstract

The present invention relates to the field of construction machinery, and in particular to a tensioning force control device for prestressed sleepers. The present invention solves the problems of a large prestress deviation and low tensioning positioning efficiency during tensioning of prestressed steel wires. The device comprises a tensioning module, a tensioning rod and a locking module. The tensioning module comprises a tensioning jack and a tensioning rod connector. The tensioning jack comprises a plurality of cylinder bodies provided with piston rods. Oil injection cavities of the plurality of cylinder bodies are communicated and oil return cavities thereof are also communicated. The piston rods are connected to the tensioning rod connector. The tensioning rod connector is temporarily connected to the tensioning rod when in use. The outer wall of the tensioning rod is provided with a nut gear in threaded fit with the tensioning rod. The tensioning rod is provided with a tensioning stepped hole. The locking module comprises a locking motor and a locking gear that is engaged with the nut gear when in use. The locking motor is connected to the locking gear. Each piston rod is used for tensioning one prestressed steel wire, and synchronized oil intake and return for the plurality of piston rods are achieved, alleviating the overlarge prestress deviation between the prestressed steel wires. The locking module allows for time-saving and labor-saving tensioning positioning.

Description

A prestressed sleeper tension control device Technical Field

[0001] The present invention relates to the technical field of construction machinery, in particular to a tensioning force control device for a prestressed sleeper. Background Art

[0002] Prestressed concrete sleepers are an important component of my country's railway system. Their production primarily utilizes a prestressing process known as pretensioning. This process requires a wire tensioning device to tension the prestressing wires. However, due to the large number of prestressing wires and the small spacing between them, tensioning them individually is difficult. Therefore, prestressing wires are typically tensioned in bundles, where multiple prestressing wires are tensioned together. In the past, the method used to tension multiple prestressed steel wires together was a single-pull-point overall tensioning method, that is, there was only one pulling point for all prestressed steel wires, and the tensioning ends of multiple prestressed steel wires were fixed on an intermediate fixed plate, and then the pulling point was used to tension the intermediate fixed plate to achieve tensioning of all prestressed steel wires together. For example, in the patent with the announcement number CN2777121Y and the name: A prestressed double T-plate steel wire tensioning device, an anchor plate (equivalent to an intermediate fixed plate) was used to fix all prestressed steel wires, and then a screw (single pulling point) was used to tension the anchor plate. The disadvantages of this tensioning method are: because the deflection, that is, the degree of bending, of each prestressed steel wire is different, the actual fixed length of each prestressed steel wire will be different after cutting, and during the tensioning process, the tensioning ends of the prestressed steel wires move synchronously as a whole under the action of the intermediate fixed plate. After the tensioning is completed, the tensioning ends of each prestressed steel wire are at the same tensioning end position, that is, all prestressed steel wires are tensioned by the same distance. In addition, the difference in the fixed length of each prestressed steel wire will cause the degree of tensioning of each prestressed steel wire to be different, resulting in prestress deviation.

[0003] In the actual production process, the difference in the fixed length of the steel wire leads to excessive prestress deviation after tensioning, which can easily cause longitudinal cracks at the ends of the sleepers after production, seriously affecting the production quality and service life of the sleepers.

[0004] Furthermore, in existing methods, after the wires are tensioned, the nut on the tensioning rod must be manually rotated to position the wires in the tensioning position. For example, the nut in patent publication number CN2777121Y, entitled "A Prestressed Double T-Slab Steel Wire Tensioning Device," is required. This method is time-consuming and labor-intensive, significantly impacting construction efficiency.

[0005] Based on the above, there is an urgent need for a prestressed sleeper tensioning force control device that can control the tensioning force deviation between steel wires to improve the tensioning construction quality and service life, and save time and effort when tensioning and positioning the steel wires, thereby improving construction efficiency.

[0006] Summary of the Invention

[0007] (1) Technical issues to be resolved

[0008] In view of the above-mentioned shortcomings and deficiencies of the prior art, the present invention provides a prestressed sleeper tensioning force control device, the purpose of which is to solve the following problems existing in the prior art: 1. Technical problems affecting the production quality and service life of sleepers due to excessive prestress deviation during the tensioning process of the prestressed steel wire; 2. The problem that the tensioning and positioning of the prestressed steel wire is time-consuming and labor-intensive, affecting the construction efficiency.

[0009] (2) Technical solution

[0010] In order to achieve the above objectives, the main technical solutions adopted by the present invention include:

[0011] An embodiment of the present invention provides a tensioning force control device for a prestressed sleeper, which mainly includes a tensioning module, a tensioning rod and a locking module. The tensioning module includes a tensioning jack and a tensioning rod connector. The tensioning jack includes a plurality of cylinders provided with piston rods. The oil filling chambers of the plurality of cylinders are connected to each other and the oil return chambers are also connected to each other. The piston rod is connected to the tensioning rod connector. The tensioning rod connector is temporarily connected to the rear end of the tensioning rod when in use. Each prestressed steel wire can be connected to a tensioning rod, each tensioning rod is connected to a tensioning rod connector, and each tensioning rod connector is connected to a piston rod, so that each prestressed steel wire corresponds to a piston rod, so as to adapt to the different fixed lengths of the prestressed steel wires and avoid all prestressed steel wires being tensioned by the same distance. At the same time, the oil filling chambers between the cylinders are connected to each other and the oil return chambers are also connected to each other, which can ensure that the tensioning force of all piston rods is the same, thereby avoiding prestress deviation of the prestressed steel wires. The tensioning rod connector is temporarily connected to the rear end of the tensioning rod when in use, which can realize the separation of the tensioning rod connector from the tensioning rod after tensioning positioning, thereby not affecting the tensioning rod connector to tension the next group of prestressed steel wires, thereby improving production efficiency.

[0012] The outer wall of the tensioning rod is sheathed with a nut gear, which engages with the outer wall of the tensioning rod through a threaded engagement. The nut gear rotates to move axially along the tensioning rod, thereby achieving tensioning positioning. The tensioning rod is internally provided with a tensioning stepped hole for connecting the prestressing wire, thereby achieving tensioning of the prestressing wire.

[0013] The locking module includes a locking motor and a locking gear. The output of the locking motor is connected to the locking gear. The locking gear engages the nut gear during operation, driving it to move axially along the tensioning rod, thereby completing the tensioning positioning.

[0014] Optionally, the tensioning module and the locking module are both arranged on a movable mounting frame, thereby realizing overall modular management of the tensioning module and the locking module, so that the tensioning module and the locking module can be moved as a whole, which is convenient and fast, and is conducive to improving production efficiency.

[0015] Optionally, the tension rod connector is internally provided with a stepped hole for connecting to the tension rod. A notch is provided on the side of the stepped hole for the tension rod to pass through, and a clip is provided at the rear end of the tension rod to engage within the stepped hole. The tension rod can be inserted into and removed from the tension rod connector through the notch, enabling a quick and convenient temporary connection between the tension rod connector and the tension rod.

[0016] Optionally, the locking gear is a half gear structure to ensure that it does not collide with the nut gear during axial movement. At the same time, when it needs to move laterally close to the nut gear, the locking gear does not contact the nut gear, thereby ensuring that the locking gear can mesh smoothly with the nut gear during operation.

[0017] Optionally, the present invention also includes a tensioning beam, which, when in use, is positioned at the end of the sleeper mold and is provided with a working through-hole for the prestressed steel wire to pass through. The tensioning beam, when in use, is positioned at the front end of the tensioning rod, for the nut gear to press against. The nut gear presses against the tensioning beam to achieve tensioning positioning. The provision of the tensioning beam eliminates the need for additional baffles at both ends of the sleeper mold, simplifying the sleeper mold structure while allowing the wire cage skeleton, after installing the prestressed steel wire, to be fully embedded within the sleeper mold, improving construction efficiency.

[0018] Optionally, a tensioning module is also included, which mainly includes a tensioning shell, a tensioning portion and a tensioning wedge. An opening is provided on one side of the tensioning shell. The tensioning portion is located in the tensioning shell, and includes a first tensioning portion and a second tensioning portion. A V-shaped groove is formed between the first tensioning portion and the second tensioning portion. The tensioning wedge extends into the V-shaped groove and can move relative to the V-shaped groove to force the second tensioning portion to extend out of the opening and press against the tensioning beam. The function of the tensioning module is to press against the tensioning beam through the second tensioning portion during tensioning, and to release the pressure on the tensioning beam after tensioning is completed to release the tensioning force. This is mainly achieved by the movement of the second tensioning portion, and the movement of the second tensioning portion is achieved by the up and down movement of the tensioning wedge.

[0019] Optionally, the release module also includes a drive unit for driving the release wedge. Its primary function is to facilitate the upward and downward movement of the release wedge within the V-groove. The drive unit includes a drive bolt and a drive bracket. The drive bracket is located at the top of the release housing. The drive bolt passes through the drive bracket and connects to the top of the release wedge. The drive bolt is threadedly connected to the drive bracket. The rotation of the bolt drives the release wedge to move. Its structure is simple and rational, and it provides high stability during movement and positioning.

[0020] Optionally, the sheet placement module also includes a vertical guide rail and an electric wrench. The vertical guide rail is located on one side of the sheet placement housing. The electric wrench is mounted on the vertical guide rail and can move along the vertical guide rail. The electric wrench engages the nut on top of the drive bolt. The electric wrench is primarily used to facilitate the tightening of the drive bolt, thereby improving production efficiency.

[0021] Optionally, a mortar retaining plate is provided in front of the tensioning beam. A mortar retaining rubber ring is provided between the tensioning beam and the mortar retaining plate. The mortar retaining plate and the mortar retaining rubber ring are used to resist mortar.

[0022] Optionally, the tensioning jack includes a main body, and a plurality of cylinders are provided on the main body, and a piston rod is provided in each cylinder. A common oil filling chamber is provided at one end of the main body, which is connected to the oil filling chamber of each cylinder, so that all oil inlet chambers are connected. A common oil return chamber is provided at the other end of the main body, which is connected to the oil return chamber of each cylinder, so that all oil return chambers are connected. The tensioning jack is an integrated multi-cylinder synchronous hydraulic cylinder structure, which can ensure that each prestressed steel wire is independently tensioned under the same tensioning force during the tensioning process to avoid prestress deviation.

[0023] (3) Beneficial effects

[0024] The beneficial effects of the present invention are as follows: a prestressed rail sleeper tensioning force control device of the present invention adopts a multi-cylinder synchronous hydraulic oil cylinder structure as a tensioning jack, and the multi-cylinder synchronous hydraulic oil cylinder is equipped with multiple piston rods, each piston rod tensions a prestressed steel wire separately, thereby avoiding the situation where the tensioning ends of multiple prestressed steel wires move and stop synchronously. At the same time, the oil filling chambers of the multiple cylinder bodies are connected and the oil return chambers are also connected, so that the multiple piston rods can be synchronously fed with oil and returned with oil, so that the tensioning force applied by the piston rods to their corresponding prestressed steel wires remains consistent, greatly improving the phenomenon of excessive prestress deviation between multiple prestressed steel wires, thereby effectively avoiding the phenomenon of longitudinal cracks easily generated at the ends of the sleeper due to excessive prestress deviation, thereby improving the production quality and service life of the sleeper.

[0025] The present invention also utilizes a locking module for tensioning and positioning. The locking module includes a locking motor and a locking gear. The locking motor drives the locking gear to rotate, causing the locking gear to engage the nut gear on the outer wall of the tensioning rod, thereby moving the nut gear along the tensioning rod to achieve tensioning and positioning. The locking module of the present invention replaces the existing method of manually rotating a nut to achieve tensioning and positioning. This saves time and effort, and the locking force is controllable, which can greatly improve construction efficiency.

[0026] Further optionally, the present invention can also set both the tensioning module and the locking module on a movable mounting frame to realize the integrated setting of the tensioning module and the locking module, so that the tensioning module and the locking module can be moved as a whole through the movable mounting frame. In this way, after completing the tensioning of one group of prestressed steel wires, the movable mounting frame can be moved to the next group of prestressed steel wires to be tensioned for operation, so as to improve construction efficiency.

[0027] Further optionally, the tension rod connector is temporarily connected to the tension rod to facilitate the detachment of the tensioning jack from the prestressed steel wires after the prestressed steel wires are tensioned and positioned, so as to tension the next set of prestressed steel wires. The temporary connection between the tension rod connector and the tension rod can be in the following form: a connecting step hole is provided inside the tension rod connector, and the connecting step hole is used to clamp the clamping head at the rear end of the tension rod. Such a structure is simple and reliable. In addition, a notch is provided on the side of the connecting step hole of the tension rod connector for the tension rod to pass through. When in use, the tension rod and the tension rod connector can be connected and disassembled through the notch. The structure is simple, and the implementation process is fast and efficient, which helps to improve construction efficiency.

[0028] Alternatively, the locking gear in the locking module can be configured as a half-gear structure. This ensures that the locking gear avoids the nut gear during axial movement, preventing direct collision with the nut gear. Furthermore, when the locking gear needs to move laterally toward the nut gear, the locking gear and the nut gear will not come into contact, ensuring smooth meshing of the locking gear and preventing toothing during operation.

[0029] Further optionally, the present invention is also provided with tensioning beams, slurry retaining plates, slurry retaining rubber rings and tensioning modules. The tensioning beams, slurry retaining plates and slurry retaining rubber rings are sleeved on both ends of the prestressed steel wire, and the tensioning module is used to press the tensioning beams. Such a setting allows both ends of the sleeper mold to adopt an open design, that is, there is no obstruction on the tensioning ends on both sides of the sleeper mold. In this way, the prestressed steel wire, slurry retaining plates, slurry retaining rubber rings, tensioning beams and tensioning rods can be installed in advance on the wire cage skeleton, and then the wire cage skeleton with the prestressed steel wire, slurry retaining plates, slurry retaining rubber rings, tensioning beams and tensioning rods installed can be smoothly hoisted and installed in the sleeper mold as a whole, and can be installed successfully in one go. Compared with the prior art method of setting a reserved hole in the end baffle of the sleeper mold, first inserting the sleeper wire cage frame into the sleeper mold, then combining the prestressed steel wire with the wire cage frame, and then passing the tensioning end of the prestressed steel wire through the reserved hole at the end of the sleeper mold, this installation method can greatly save operation time, that is, the installation time of the wire cage frame and the tensioning time of the prestressed steel wire will be greatly improved.

[0030] In summary, the present invention has effectively solved the technical problems existing in the prior art, such as the excessive prestress deviation during the prestressing process affecting the production quality and service life of the sleepers, and the technical problems that the steel wire tensioning positioning is time-consuming and labor-intensive, affecting the construction efficiency, and is conducive to promotion and application. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] FIG1 is a perspective schematic diagram of a prestressed sleeper tensioning force control device of the present invention in a working state (prestressed steel wire is not shown);

[0032] FIG2 is another perspective schematic diagram of a prestressed sleeper tensioning force control device of the present invention in a working state (prestressed steel wire is shown);

[0033] FIG3 is a perspective view of the tensioning principle of a prestressed sleeper tensioning force control device of the present invention in a working state;

[0034] FIG4 is a schematic diagram of FIG3 from another angle;

[0035] FIG5 is a perspective schematic diagram showing the main structure of a prestressed sleeper tensioning force control device of the present invention;

[0036] FIG6 is a schematic diagram of FIG5 from another angle;

[0037] FIG7 is a perspective schematic diagram of a tensioning jack at one angle;

[0038] FIG8 is a perspective schematic diagram of the tensioning jack from another angle;

[0039] Figure 9 is an end view of the tensioning jack;

[0040] Figure 10 is a side view of the tensioning jack;

[0041] FIG11 is a cross-sectional view taken along line AA of FIG9 ;

[0042] FIG12 is a partial view of the BB cross-sectional view of FIG9 rotated 90° counterclockwise;

[0043] Figure 13 is an exploded view of the tension rod and the nut gear;

[0044] Figure 14 is a side view of the structure of the tension rod (the nut and gear are not shown);

[0045] FIG15 is an axial cross-sectional view of FIG14;

[0046] FIG16 is a perspective schematic diagram of a tension rod connector;

[0047] FIG17 is a partially cutaway perspective view of the sheet-laying module;

[0048] FIG18 is a partial cross-sectional view of the release module;

[0049] FIG19 is a partial cross-sectional view of another form of a tensioning module;

[0050] FIG20 is a cross-sectional view of the active connection between the drive bolt and the top end of the wedge;

[0051] FIG21 is a top view of the receiving box;

[0052] FIG22 is a perspective view of a vertical guide rail installed on the side wall of a housing;

[0053] Figure 23 is a schematic diagram showing the connection between the prestressed steel wire and the tension rod;

[0054] FIG24 is a schematic diagram of a form of a wedge;

[0055] FIG25 is a schematic diagram showing the principle of connecting the fixed end of the prestressed steel wire to the tension beam;

[0056] FIG26 is a schematic diagram showing the position of the locking gear when the nut gear presses against the tension beam;

[0057] FIG27 is an enlarged view of the dotted circle portion in FIG3 (the dotted circle in FIG3 only represents the enlarged area, not the specific component);

[0058] FIG28 is a partial cross-sectional view of the locking gear installation position;

[0059] FIG29 is a schematic diagram of a working through hole for the fixed end of the prestressed steel wire to pass through;

[0060] Figure 30 is a schematic diagram of the form of a working through hole for the tensioning end of the prestressed steel wire to pass through.

[0061] [Explanation of the accompanying figures] 1: tensioning module; 101: tensioning jack; 1011: main body; 1012: cylinder; 10121: oil filling chamber; 10122: oil return chamber; 1013: piston rod; 1014: common oil filling chamber; 1015: common oil return chamber; 102: tensioning rod connector; 1021: first internal threaded through hole; 103: connecting stepped hole; 1031: connecting small hole section; 1032: connecting large hole section; 1033: first stepped platform; 104: notch; 2: tensioning rod; 201: nut gear; 2011: second internal threaded through hole; 202: tensioning Stepped hole; 2021: tensioning small hole section; 2022: tensioning large hole section; 2023: second step platform; 203: clamping head; 3: locking module; 301: locking motor; 302: locking gear; 303: reducer; 305: gear shaft; 4: tensioning beam; 401: working through hole; 5: tensioning module; 501: tensioning shell; 5011: flat plate; 502: tensioning part; 5021: first tensioning part; 5022: second tensioning part 503: Wedge; 504: Opening; 505: Drive bolt; 5051: Nut; 506: Drive bracket; 507: Vertical guide rail; 508: Electric wrench; 6: Sleeper mold; 602: Groove; 603: Limit baffle; 7: Slurry stop plate; 8: Slurry stop rubber ring; 9: Movable mounting bracket; 901: Rectangular frame; 9011: Rectangular frame upper frame; 9012: Rectangular frame lower frame; 9013: Rectangular frame side frame; 902: Mounting plate; 9021: Mounting plate through hole; 9022: Horizontal support arm; 9023: Support plate; 9024: Bearing; 10: Prestressed steel wire; 11: Tensioning pier head; 12: Accommodation box; 121: Top cover; 122: Connection hole; 13: Follow-up disc; 14: "7"-shaped baffle; 141: Horizontal beam; 142: Vertical beam; 15: Guide rail mounting plate; 16: Fixed pier head; 17: Horizontal brace; 18: Limiting top plate; 19: Fastening vertical plate. DETAILED DESCRIPTION

[0062] In order to better explain the present invention and facilitate understanding, the present invention is described in detail below with reference to the accompanying drawings and specific embodiments.

[0063] A prestressed sleeper tensioning force control device proposed in an embodiment of the present invention includes a tensioning rod, a tensioning module and a locking module. The tensioning module includes a tensioning jack and a tensioning rod connector. The tensioning jack is a multi-cylinder synchronous hydraulic cylinder structure. The tensioning jack is connected to the tensioning rod connector. The tensioning rod connector is temporarily connected to the rear end of the tensioning rod when in use. The outer wall of the tensioning rod is provided with a nut gear, and the nut gear is threadedly engaged with the outer wall of the tensioning rod. A tensioning stepped hole is provided inside the tensioning rod. The locking module includes a locking motor and a locking gear. The output end of the locking motor is connected to the locking gear. The locking gear engages the nut gear when in use. It effectively solves the technical problems existing in the prior art that the production quality and service life of the sleeper are affected by excessive prestress deviation during the tensioning process of the steel wire, and the technical problems that the tensioning positioning of the steel wire is time-consuming and labor-intensive, affecting the construction efficiency.

[0064] To better understand the above technical solutions, exemplary embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present invention are shown in the accompanying drawings, it should be understood that the present invention can be implemented in various forms and should not be limited by the embodiments described herein. Instead, these embodiments are provided to enable a clearer and more thorough understanding of the present invention and to fully convey the scope of the present invention to those skilled in the art.

[0065] Example 1:

[0066] For the convenience of description, the “front” referred to below is based on the longitudinal Y direction and is the direction toward the sleeper mold 6 .

[0067] 1 to 6 , the present invention provides a tensioning force control device for a prestressed sleeper, which mainly includes a tensioning module 1, a tensioning rod 2, and a locking module 3. The tensioning module 1 is used to tension a prestressed steel wire 10, the tensioning rod 2 is used to hook and hold the prestressed steel wire 10, and the locking module 3 is used to lock the prestressed steel wire 10 in the tensioning position to achieve tension positioning.

[0068] The tensioning module 1 includes a tensioning jack 101 and a tensioning rod connector 102, and the front end of the tensioning jack 101 is connected to the rear end of the tensioning rod connector 102. Specifically, the tensioning jack 101 can be an integrated multi-cylinder synchronous hydraulic cylinder structure. The "integrated multi-cylinder synchronous hydraulic cylinder structure" can take the following form: Referring to Figures 7-12, the tensioning jack 101 includes a main body 1011. A plurality of cylinder bodies 1012 parallel to each other are provided on the main body 1011, and this structure is called "integrated multi-cylinder". A piston rod 1013 is provided in each cylinder body 1012. The front end of the piston rod 1013 is connected to the rear end of the tensioning rod connector 102. Furthermore, the front end of the piston rod 1013 and the tension rod connector 102 can be connected by a threaded connection. For example, referring to FIG16 , a first internally threaded through hole 1021 can be provided at the rear end of the tension rod connector 102, and then an externally threaded screw can be provided at the front end of the piston rod 1013, and the externally threaded screw can be screwed into the first internally threaded through hole 1021 to achieve a threaded connection between the piston rod 1013 and the tension rod connector 102. This threaded connection can facilitate the disassembly of the tension rod connector 102, making the maintenance of the tension rod connector 102 more convenient.

[0069] The advantage of the aforementioned "integrated multi-cylinder" structure is that each individual piston rod 1013 can independently correspond to a prestressed steel wire 10 during use. Each piston rod 1013 can independently extend and retract to achieve independent tensioning of each prestressed steel wire 10. This can adapt to the different lengths of each prestressed steel wire 10 and ensure the tensioning effect of each prestressed steel wire 10. In addition, integrating multiple cylinders 1012 into a single body 1011 can, on the one hand, reduce the use of connecting components and improve the integrity and stability of the structure; on the other hand, it can facilitate the overall installation and disassembly, improving maintenance efficiency; and on the other hand, it can save space after installation.

[0070] Further, optionally, referring to Figures 11 and 12, a common oil filling chamber 1014 is provided at one end of the main body 1011 of the tensioning jack 101, and the common oil filling chamber 1014 is connected to the oil filling pipeline. The common oil filling chamber 1014 is connected to the oil filling chamber 10121 in each cylinder body 1012, so that each oil filling chamber 10121 can be filled with oil at the same time and in the same amount, i.e., synchronous oil filling. A common oil return chamber 1015 is provided at the other end of the main body 1011, and the common oil return chamber 1015 is connected to the oil return pipeline. The common oil return chamber 1015 is connected to the oil return chamber 10122 of each cylinder body 1012 to ensure that each oil return chamber 10122 returns oil at the same time and in the same amount, i.e., synchronous oil return. The above structure is called a "synchronous hydraulic cylinder". The advantage of this "synchronous hydraulic cylinder" is that it ensures that the tensioning stress provided by each piston rod 1013 is the same, so as to minimize prestress deviation.

[0071] The tension rod connector 102 is temporarily connected to the rear end of the tension rod 2 when in use. The "temporary connection" mentioned here means that the tension rod connector 102 and the tension rod 2 are detachable, that is, when tensioning is required, the tension rod connector 102 is connected to the tension rod 2, and after the tensioning is completed, during the concrete pouring process, the tension rod connector 102 is disassembled and separated from the tension rod 2 to facilitate the use of the tension rod connector 102 to tension the next group of prestressed steel wires 10. The "temporary connection" between the tension rod connector 102 and the tension rod 2 can adopt any of the existing known methods. For example, a hook-type "temporary connection" can be adopted, that is, a first hook is set at the rear end of the tension rod 2, and a second hook is set at the front end of the tension rod connector 102. When connection is required, the second hook is hooked with the first hook. This hooking method belongs to the known technology and will not be described here.

[0072] Of course, the aforementioned "temporary connection" can also take the following form: Referring to Figures 5 and 13-16, a connection stepped hole 103 is provided inside the tension rod connector 102. The connection stepped hole 103 is divided into a connection small hole section 1031 and a connection large hole section 1032. The hole diameter of the connection small hole section 1031 is smaller than the hole diameter of the connection large hole section 1032. The connection small hole section 1031 is located at the front end of the connection large hole section 1032, and the connection small hole section 1031 and the connection large hole section 1032 are coaxial. A first step 1033 is formed at the connection point between the connection small hole section 1031 and the connection large hole section 1032. A notch 104 is provided on the side of the connection stepped hole 103 for the tension rod 2 to pass through. A clamping head 203 is provided at the rear end of the tension rod 2 for clamping into the connection stepped hole 103. When the tension rod 2 needs to be connected to the tension rod connector 102, the rear end of the tension rod 2 is moved along the transverse X direction and passed through the notch 104, so that the clamp 203 at the rear end of the tension rod 2 is inserted into the connecting large hole section 1032. At this time, the other parts of the tension rod 2 pass through the connecting small hole section 1031. In this way, during tensioning, the clamp 203 can be clamped at the first step 1033, so that the tension rod connector 102 can pull the tension rod 2 to move, thereby achieving tensioning of the prestressed steel wire 10. After the tensioning is completed, the piston rod 1013 can be used to drive the tension rod connector 102 to move along the longitudinal Y direction, so that the clamp 203 is disengaged from the first step 1033. Then, the tension rod connector 102 is moved along the transverse X direction so that the tension rod 2 can pass through the notch 104 and move out of the tension rod connector 102, completing the disassembly between the tension rod connector 102 and the tension rod 2. This structure is simple and efficient, and can quickly realize the connection and disassembly between the tension rod connector 102 and the tension rod 2, thereby improving construction efficiency.

[0073] In this embodiment, the outer wall of the tension rod 2 is sheathed with a nut gear 201, which engages with the outer wall of the tension rod 2. Referring to Figure 13 , the structure of the nut gear 201 is an externally threaded internally threaded structure, i.e., it is a gear structure as a whole, with a second internally threaded through-hole 2011 defined in the center of the gear structure. The outer wall of the tension rod 2 is provided with external threads, and the nut gear 201 is sheathed on the outer wall of the tension rod 2 through the second internally threaded through-hole 2011, which engages with the external threads of the outer wall of the tension rod 2.

[0074] Referring to Figure 15 , in this embodiment, a tensioning stepped hole 202 is provided within the tensioning rod 2. This tensioning stepped hole 202 is a through hole and is used to attach the prestressed steel wire 10. This tensioning stepped hole 202 includes a small tensioning hole section 2021 and a large tensioning hole section 2022. The diameter of the small tensioning hole section 2021 is smaller than that of the large tensioning hole section 2022. The small tensioning hole section 2021 is located at the front end of the large tensioning hole section 2022 and is coaxial with the large tensioning hole section 2022. A second step 2023 is formed at the junction of the small tensioning hole section 2021 and the large tensioning hole section 2022. Referring to Figure 23, when the prestressed steel wire 10 needs to be hung, the tensioning end of the prestressed steel wire 10 is passed through the tensioning small hole section 2021 and the tensioning large hole section 2022 in sequence, and the tensioning end of the prestressed steel wire 10 is extended from the rear end of the tensioning rod 2. Then, a tensioning pier 11 is set at the tensioning end of the prestressed steel wire 10. The tensioning pier 11 can be set using existing steel wire tensioning pier equipment, which will not be described here. Then, the tensioning rod 2 is moved along the axial direction of the prestressed steel wire 10, that is, in the longitudinal Y direction, so that the tensioning pier 11 can be clamped at the second step 2023, and then the prestressed steel wire 10 can be tensioned.

[0075] 3 and 5 , in this embodiment, the locking module 3 includes a locking motor 301 and a locking gear 302. The output end of the locking motor 301 is connected to the locking gear 302. Typically, the locking motor 301 is connected to the locking gear 302 via a speed reducer 303. The locking motor 301 drives the locking gear 302 to rotate, allowing the locking gear 302 to engage the nut gear 201 and rotate.

[0076] Alternatively, the tensioning module 1 and the locking module 3 can both be mounted on a movable mounting frame 9, that is, the tensioning module 1 and the locking module 3 can be configured as a movable integrated modular structure. Specifically, referring to Figures 5 and 6 , the movable mounting frame 9 includes a rectangular frame 901 and a mounting plate 902. The rectangular frame 901 includes a rectangular upper frame 9011, a rectangular lower frame 9012, and two rectangular side frames 9013, which are arranged parallel to each other. The rectangular upper frame 9011 and the rectangular lower frame 9012 are respectively located at the upper and lower ends of the two rectangular side frames 9013, so that the rectangular upper frame 9011, the rectangular lower frame 9012, and the two rectangular side frames 9013 form a rectangular frame structure, thus being referred to as the rectangular frame 901. The front and rear ends of the rectangular frame 901 are open, and the mounting plate 902 is disposed at the open front end of the rectangular frame 901.

[0077] The main body 1011 of the tensioning jack 101 is located within the rectangular frame 901. The main body 1011 is fixedly connected to the inner wall of the rectangular frame 901 or the mounting plate 902. This "fixed connection" can be achieved by directly welding the main body 1011 to the inner wall of the rectangular frame 901 or the mounting plate 902, or by temporarily connecting the main body 1011 to the inner wall of the rectangular frame 901 or the mounting plate 902 using bolts by providing bolt holes in the inner wall of the rectangular frame 901 or the mounting plate 902. The specific "fixed connection" method can adopt any existing implementation method and is not detailed here.

[0078] 5 , the piston rod 1013 passes through the mounting plate through hole 9021 on the mounting plate 902 and is connected to the rear end of the tension rod connector 102. The diameter of the mounting plate through hole 9021 is larger than the diameter of the piston rod 1013 so as not to hinder the telescopic action of the piston rod 1013.

[0079] 5 and 28 , a forward-extending transverse support arm 9022 is provided on the mounting plate 902, and a support plate 9023 is mounted at the front end of the transverse support arm 9022. A support hole is provided on the support plate 9023, and a bearing 9024 is provided in the support hole. The locking gear 302 is located in front of the support plate 9023, and the locking gear 302 is provided on a gear shaft 305. The gear shaft 305 extends backward after passing through the bearing 9024 and is connected to the output end of the reducer 303. The reducer 303 is an angular reducer, which is a finished product purchased directly. For example, it can be a high-precision angular planetary reducer with a right angle, so that the output shaft of the locking motor 301 is 90° to the gear shaft 305, thus forming a vertical installation form of the locking motor 301. The advantage of such an arrangement is that it can save space occupied in the longitudinal Y direction. To ensure the stability of the installation, the locking motor 301 can be fixed to the mounting plate 902 through a mounting base and bolts and other components, that is, mounting screw holes are set on the mounting plate 902, and the mounting holes on the mounting base of the locking motor 301 are matched with the mounting screw holes on the mounting plate 902, and then the bolts are passed through the mounting holes on the mounting base of the locking motor 301 and then threadedly engaged with the mounting screw holes on the mounting plate 902.

[0080] The locking gear 302 can be located above, below or to the side of the tensioning rod connector 102, as long as the locking gear 302 can be engaged with the nut gear 201 on the tensioning rod 2 by rotating during tensioning construction.

[0081] Further optionally, referring to Figure 5, the locking gear 302 can be set to a half-gear structure. Since the spacing between the multiple prestressed steel wires 10 is small, the locking gear 302 adopts a half-gear structure design, which can ensure that it will not collide with the corresponding nut gear 201 during the axial movement, that is, the longitudinal Y direction. At the same time, when it is necessary to move along the transverse X direction and approach the corresponding nut gear 201, the locking gear 302 can be rotated to a position where it will not contact the corresponding nut gear 201, so that the locking gear 302 can be smoothly meshed with the corresponding nut gear 201 when it needs to rotate, and no top tooth phenomenon occurs. Further preferably, the locking gear 302 and the nut gear 201 both adopt involute gears to further ensure the smooth meshing of the locking gear 302 and the nut gear 201.

[0082] Further optionally, the present invention may also include a tensioning beam 4. When in use, the tensioning beam 4 is arranged at the front end of the tensioning rod 2, that is, at both ends of the sleeper mold 6. When the prestressed steel wire 10 is tensioned, the tensioning beam 4 is pressed by the nut gear 201 to achieve tensioning positioning. A working through hole 401 for the prestressed steel wire 10 to pass through is provided on the tensioning beam 4. After the tensioning beam 4 is provided, the two ends of the sleeper mold 6 can be designed to be open, that is, the two ends of the sleeper mold 6 are open. The open design at both ends of the sleeper mold 6 allows the sleeper wire cage skeleton with the prestressed steel wire 10 installed to be smoothly hoisted and installed in the sleeper mold 6 as a whole, and the installation is successful at one time. This form can be called "integrated hoisting". The existing methods all adopt the "step-by-step installation" method, and the "step-by-step installation" method is that there are baffles at the ends of the sleeper mold. First, holes are reserved in the end baffles of the sleeper mold. Then, a wire cage is placed inside the mold. The prestressed wire 10 is then installed on the cage, with both ends of the prestressed wire 10 passing through the holes in the end baffles of the mold. Compared to the traditional "step-by-step installation" method, this "integrated hoisting" method saves steps and time, significantly improving the efficiency of wire cage installation and prestressed wire 10 tensioning.

[0083] Further optionally, referring to Figures 17-19 , the present invention may also include a tensioning module 5 for the tensioning beam 4. This module 5 is primarily used to press against the tensioning beam 4. The module 5 comprises a tensioning housing 501, a tensioning portion 502, and a tensioning wedge 503. An opening 504 is provided on one side of the tensioning housing 501. The tensioning housing 501 is mounted on the side of the sleeper mold 6 during use, either by direct welding or by other known methods. The expansion unit 502 is located within the expansion housing 501 and includes a first expansion unit 5021 and a second expansion unit 5022. A V-shaped groove is formed between the first expansion unit 5021 and the second expansion unit 5022. Specifically, the first expansion unit 5021 and the second expansion unit 5022 each have a single-bevel prism structure. The surface of the first expansion unit 5021 facing the second expansion unit 5022 is an inclined surface, while the remaining surfaces are straight surfaces. The surface of the second expansion unit 5022 facing the first expansion unit 5021 is an inclined surface, while the remaining surfaces are also straight surfaces. Thus, a V-shaped groove is formed between the inclined surfaces of the first expansion unit 5021 and the second expansion unit 5022. The expansion wedge 503 extends into the V-shaped groove and is movable relative to the V-shaped groove, with the movement being vertical. The movement of the tensioning wedge 503 presses the second tensioning portion 5022, allowing it to translate and extend out of the opening 504 to press against the tensioning beam 4. The second tensioning portion 5022, together with the nut gear 201, presses against the tensioning beam 4 to achieve tensioning and positioning of the prestressed steel wire 10. Specifically, after the prestressed steel wire 10 passes through the tensioning beam 4 and connects to the tensioning rod 2, the second tensioning portion 5022 presses against the front end of the tensioning beam 4. After the tensioning rod 2 tensions the prestressed steel wire 10, the nut gear 201 moves by screwing and presses against the rear end of the tensioning beam 4, completing the tensioning and positioning of the prestressed steel wire 10. The use of the tensioning module 5 can make the stress on the tensioning beam 4 more stable, thereby making the state of the tensioning beam 4 more stable. In addition, the tensioning module 5 also plays the role of releasing the tensioning force. That is, when the tensioning is completed, the tensioning wedge 503 can be moved to release the low pressure on the second tensioning part 5022, and then the second tensioning part 5022 releases the low pressure on the tensioning beam 4, completing the release of the tensioning stress. The release process is simple and fast, which is conducive to improving production efficiency.

[0084] It should be noted that the aforementioned "V-shaped groove" can be a groove that gradually shrinks from top to bottom, as shown in FIG18 . In this case, the downward movement of the tensioning wedge 503 forces the second tensioning portion 5022 to translate and press against the tensioning beam 4. Alternatively, the aforementioned "V-shaped groove" can be a groove that gradually expands from top to bottom, as shown in FIG19 . In this case, the upward movement of the tensioning wedge 503 forces the second tensioning portion 5022 to translate and press against the tensioning beam 4. The choice can be made based on actual production circumstances.

[0085] Further optionally, the above-mentioned sheet-releasing module 5 further includes a driving unit, which is used to drive the sheet-releasing wedge 503 to move up and down. The driving unit includes a driving bolt 505 and a driving bracket 506. The driving bracket 506 is located at the top of the sheet-releasing shell 501, and the driving bracket 506 can be connected to the top of the sheet-releasing shell 501 by welding. The driving bolt 505 passes through the driving bracket 506 and is connected to the top of the sheet-releasing wedge 503. The driving bolt 505 is threadedly connected to the driving bracket 506, that is, an internal threaded through hole of the driving bracket is provided on the driving bracket 506, and the driving bolt 505 with an external thread passes through the internal threaded through hole of the driving bracket and is threadedly engaged with the internal threaded through hole of the driving bracket. The driving bolt 505 can be rotated relative to the driving bracket 506 to achieve up and down movement, so that the driving bolt 505 can drive the sheet-releasing wedge 503 to move up and down relative to the "V-shaped groove".

[0086] It should be noted that the drive bolt 505 can be fixedly or flexibly connected to the top of the release wedge 503. When the drive bolt 505 is fixedly connected to the top of the release wedge 503, the release wedge 503 rotates together with the drive bolt 505. In this case, the release wedge 503 can be configured as a truncated cone structure, allowing it to rotate within the "V-shaped groove." The truncated cone structure is shown in Figure 24. The slope of the side of the truncated cone structure is the same as the slope of the inclined surface on the first release portion 5021 and the inclined surface on the second release portion 5022. To ensure the rotation of the release wedge 503, lubricating oil can be applied to the outer surface of the release wedge 503.

[0087] When the driving bolt 505 is movably connected to the top of the releasing wedge 503, as shown in Figures 17, 18, 19, 20, and 21, a housing 12 is positioned at the top of the releasing wedge 503. The interior of the housing 12 is a cylindrical cavity, which, as shown in Figure 21, is circular in top view. A follower disc 13 is positioned within the cavity, which is rotatable within the cavity. A connecting hole 122 is defined in the top cover 121 of the housing 12. The bottom end of the driving bolt 505 passes through the connecting hole 122, extends into the housing 12, and connects to the follower disc 13. The diameter of the connecting hole 122 is larger than that of the driving bolt 505 and smaller than that of the follower disc 13. The diameter of the connecting hole 122 is sufficient to ensure that it does not hinder the rotation of the driving bolt 505. 20 , the specific installation process is as follows: first, weld the receiving box 12 to the top of the wedge 503; then, screw the driving bolt 505 from top to bottom through the internal threaded hole of the driving bracket 506; and from the lower end of the driving bolt 505, put the top cover 121 on the outer periphery of the driving bolt 505; then weld the follower disc 13 to the bottom end of the driving bolt 505; and continue to screw the driving bolt 505 so that the follower disc 13 is placed in the cavity of the receiving box 12; then move the top cover 121 downward so that it covers the top of the receiving box 12; and weld the top cover 121 to the receiving box 12 as one, or use bolts to fix the top cover 121 to the receiving box 12. The movably connected drive bolt 505 to the top of the unfolding wedge 503 prevents the unfolding wedge 503 from rotating with the drive bolt 505 during operation. The unfolding wedge 503 can have a prism-shaped structure, as shown in FIG17 . The slope of the side of the prism-shaped structure is the same as that of the inclined surfaces on the first unfolding portion 5021 and the second unfolding portion 5022, allowing the side of the prism-shaped structure to conform to the shape of the "V-shaped groove." To ensure smooth movement of the unfolding wedge 503, lubricating oil can be applied to the outer surface of the unfolding wedge 503.

[0088] For the above-mentioned sheet-releasing module 5, a "7"-shaped baffle 14 can be provided at a position corresponding to the opening 504 on the outside of the sheet-releasing shell 501. The "7"-shaped baffle 14 includes a horizontal beam 141 and a vertical beam 142. The horizontal beam 141 is located at the top of the vertical beam 142 and forms a "7"-shaped structure with the vertical beam 142. The horizontal beam 141 is connected to the side of the sheet-releasing shell 501, and the bottom of the horizontal beam 141 is higher than the top of the opening 504 so as not to hinder the second sheet-releasing part 5022 from extending from the opening 504. A gap is left between the vertical beam 142 and the opening 504. The size of the gap depends on the distance that the second sheet-releasing part 5022 extends from the opening 504, that is, the gap is not less than the distance that the second sheet-releasing part 5022 needs to extend from the opening 504. The bottom of the vertical beam 142 can be connected to the flat plate 5011 at the bottom of the unfolding shell 501. The vertical beam 142 can prevent the second unfolding portion 5022 from falling off from the opening 504 during transportation or installation.

[0089] Further, the sheet placement module 5 may optionally include a vertical guide rail 507 and an electric wrench 508. The electric wrench 508 is primarily used to tighten the drive bolt 505, and the vertical guide rail 507 is used to limit the vertical movement of the electric wrench 508. Optionally, a dovetail guide rail may be provided on the vertical guide rail 507. The electric wrench 508 is connected to one end of the cross brace 17. The other end of the cross brace 17 is provided with a dovetail groove. This dovetail groove cooperates with the dovetail guide rail on the vertical guide rail 507, allowing the electric wrench 508 to move up and down along the vertical guide rail 507.

[0090] The vertical guide rail 507 is located on one side of the tensioning housing 501 and can be directly fixed to the side of the tensioning housing 501 by welding or bolting, as shown in Figure 22. The vertical guide rail 507 can also be fixed to the sleeper mold 6 when in use, as shown in Figures 1 and 2. In this form, the tensioning module 5 is located in the grooves 602 on both sides of the sleeper mold 6. The bottom of the tensioning housing 501 can be fixed to the bottom of the groove 602 by welding or other methods. Alternatively, a limit baffle 603 can be directly provided in the groove 602, and the tensioning housing 501 can be placed directly against the limit baffle 603. That is, the side of the tensioning housing 501 with the opening 504 facing the tensioning beam 4, while the other side of the tensioning housing 501 is close to the limit baffle 603. A guide rail mounting plate 15 is provided at the top of the groove 602, and the guide rail mounting plate 15 is located near the tensioning module 5. The vertical guide rail 507 can be installed on the guide rail mounting plate 15. The rotating sleeve of the electric wrench 508 engages with the nut 5051 on the top of the driving bolt 505, and the driving bolt 505 is driven to rotate by the rotating sleeve.

[0091] In addition, for the above-mentioned tensioning beam 4, a slurry blocking plate 7 can also be set in front of the tensioning beam 4. The slurry blocking plate 7 has the function of blocking cement slurry and serving as the end baffle of the sleeper mold 6. A through hole is reserved on the slurry blocking plate 7 for the prestressed steel wire 10 to pass through. The diameter of the reserved through hole is determined according to the diameter of the prestressed steel wire 10. For example, in this embodiment, the diameter of the reserved through hole can be 8 mm. The tensioning beam 4 is installed on the rear side of the slurry blocking plate 7. A slurry blocking rubber ring 8 is installed between the slurry blocking plate 7 and the tensioning beam 4. The slurry blocking rubber ring 8 is sleeved on the prestressed steel wire 10. The slurry blocking rubber ring 8 is used to prevent cement slurry from seeping out from the reserved through hole of the slurry blocking plate 7 and the working through hole 401 of the tensioning beam 4 and contaminating equipment such as the tensioning rod 2. Furthermore, the slurry-blocking rubber ring 8 can also be located in the stepped working through hole 401. Referring to Figure 29, the working through hole 401 used to clamp the fixed pier head 16 is a double-sided stepped hole, that is, the stepped hole is divided into three sections, and the diameter of the middle section of the through hole is smaller than the diameter of the through holes on both sides. The through holes on both sides are used to accommodate the slurry-blocking rubber ring 8 and the fixed pier head 16 respectively. At this time, the other working through holes 401 that do not cooperate with the fixed pier head 16 can be set as single-sided stepped holes, that is, referring to Figure 30, the working through hole 401 only needs to be divided into two sections with different diameters, and the diameter of the through hole in the front section is larger than the diameter of the through hole in the rear section, so as to be used to accommodate the slurry-blocking rubber ring 8. The ultimate goal is to ensure that the slurry-blocking rubber ring 8, the fixed pier head 16, etc. do not protrude from the tensioning beam 4.

[0092] Further explanation: The structure, principle, and usage process of the present invention are further sorted out in the form of examples with reference to Figures 1 to 30. This description is merely an example to combine the above-mentioned multiple preferred embodiments for the convenience of comprehensive description, but this description is not a limitation of the embodiments of the present application. The description is as follows:

[0093] For the sake of convenience, the "prestressed sleeper tensioning force control device" of the present invention will be referred to as the "tensioning control device" below.

[0094] A single sleeper typically has ten prestressed steel wires 10. This "Further Description" utilizes a bidirectional tensioning scheme, with a "tensioning control device" of the present invention positioned at each end of the ten prestressed steel wires 10. Each tensioning jack 101 in the "tensioning control device" is equipped with five cylinders 1012, staggered and arranged according to the positions of the sleeper's prestressed steel wires 10. See Figure 5 for their arrangement. Two tensioning control devices can each tension the five prestressed steel wires 10.

[0095] In this "further explanation", both ends of the sleeper mould 6 are open, that is, no baffles are provided.

[0096] The specific construction process is as follows: first, a steel cage skeleton is fabricated, and then ten prestressed steel wires 10 are installed on the skeleton. It should be noted that the steel cage skeleton and its fabrication process are well-known techniques and are therefore not shown in the figures. Then, slurry retaining plates 7, slurry retaining rubber rings 8, and tensioning beams 4 are sequentially inserted from both ends of the ten prestressed steel wires 10.

[0097] Then, the ten prestressed steel wires 10 are divided into two groups for separate operations. For ease of description, the two groups of prestressed steel wires 10 are referred to as the first group of prestressed steel wires and the second group of prestressed steel wires. The first group of prestressed steel wires and the second group of prestressed steel wires each consist of five prestressed steel wires 10.

[0098] First, operate on the first group of prestressed steel wires: Referring to Figure 25, one end of the five prestressed steel wires 10 in the group is used as a fixed end, and a fixed pier head 16 is set at the fixed end. The fixed pier head 16 is used to be clamped at the working through hole 401 on the tensioning beam 4. Preferably, referring to Figure 29, the working through hole 401 can be set as a stepped hole, so that when the fixed pier head 16 is at the working through hole 401, the rear end face of the fixed pier head 16 will not protrude from the rear end face of the tensioning beam 4. Such a setting can reduce the amount of prestressed steel wires 10 to a certain extent. Referring to Figure 23, the other end of the five prestressed steel wires 10 in the group is used as a tensioning end, and the tensioning end is sequentially passed through the tensioning small hole section 2021 and the tensioning large hole section 2022 of the tensioning rod 2 and then extends from the rear end of the tensioning rod 2, and then a tensioning pier head 11 is set at the tensioning end of the five prestressed steel wires 10.

[0099] Then operate on the second group of prestressed steel wires: one end of the five prestressed steel wires 10 in the group is used as a fixed end, and a fixed pier head 16 is set at the fixed end. The fixed pier head 16 is used to be clamped at the working through hole 401 on the tensioning beam 4. Preferably, referring to Figure 29, the working through hole 401 can be set as a stepped hole, so that when the fixed pier head 16 is at the working through hole 401, the rear end face of the fixed pier head 16 can be aligned with the rear end face of the tensioning beam 4. Such a setting can reduce the amount of prestressed steel wire 10 to a certain extent. The other end of the five prestressed steel wires 10 in the group is used as a tensioning end. After the tensioning end passes through the tensioning small hole section 2021 and the tensioning large hole section 2022 of the tensioning rod 2 in sequence, it extends from the rear end of the tensioning rod 2, and then a tensioning pier head 11 is set at the tensioning end of the five prestressed steel wires 10. The specific form is also referred to Figure 23.

[0100] It should be noted here that the fixed ends and tensioning ends in the first group of prestressed steel wires are in opposite directions to the fixed ends and tensioning ends in the second group of prestressed steel wires, that is, the fixed ends in the first group of prestressed steel wires correspond to the tensioning ends in the second group of prestressed steel wires, and the tensioning ends in the first group of prestressed steel wires correspond to the fixed ends in the second group of prestressed steel wires.

[0101] The wire cage frame, with the prestressed steel wires 10 installed, is hoisted into the open-ended sleeper mold 6. The sleeper mold 6 is provided with grooves 602 on its left and right sides in the longitudinal direction Y, with two tensioning modules 5 positioned within each groove 602. The two tensioning modules 5 within each groove 602 are located at either end of the groove 602. That is, referring to Figures 1 and 2, a tensioning module 5 is positioned on either side of each end of the sleeper mold 6, for a total of four tensioning modules 5 within the entire sleeper mold 6.

[0102] In this "further explanation", the installation method of the vertical guide rail 507 is as follows: a guide rail mounting plate 15 is provided on the top of the groove 602, and the vertical guide rail 507 is mounted on the guide rail mounting plate 15. The guide rail mounting plate 15 is located close to the sheet placing module 5.

[0103] In this "further explanation", the "V-shaped groove" in the sheet placing module 5 is in a form of gradually becoming smaller from top to bottom as shown in Figures 17 and 18.

[0104] In this "Further Description", the area of ​​the slurry guard 7 is smaller than that of the tensioning beam 4, and it only needs to be able to cover the openings at both ends of the sleeper mold 6. The tensioning beam 4 needs to extend in the transverse X direction to the position where the two grooves 602 are located so that the second tensioning portion 5022 can press against it.

[0105] Move the two "tensioning control devices" to the two ends of the sleeper mold 6, and insert the clamping head 203 at the rear end of the tensioning rod 2 into the connecting large hole section 1032 of the tensioning rod connector 102 through the notch 104. It should be noted here that the notches 104 on all the tensioning rod connectors 102 in each "tensioning control device" are oriented in the same direction to facilitate the simultaneous insertion of all the tensioning rods 2 into the tensioning rod connector 102.

[0106] After the above operations are completed, the driving bolt 505 is rotated and moved downward by the electric wrench 508 , thereby driving the second tensioning portion 5022 to extend out of the opening 504 so as to be used to press the tensioning beam 4 .

[0107] Afterwards, the oil pump is activated, causing the piston rod 1013 to move the tensioning rod connector 102 in the longitudinal direction Y, away from the sleeper mold 6. When the clamping head 203 at the rear end of the tensioning rod 2 engages the first step 1033, the tensioning rod 2 and the tensioning rod connector 102 move synchronously. When the tensioning pier 11 engages the second step 2023, the tensioning rod 2 begins to tension the prestressed steel wires 10. Initial tensioning is first performed on the prestressed steel wires 10, i.e., all prestressed steel wires 10 are initially tensioned to a straight state. At this point, the fixed pier 16 at the fixed end of the prestressed steel wire 10 engages the working through hole 401, causing the tensioning beam 4 to initially press against the second tensioning portion 5022. In other words, at this point, the second tensioning portion 5022 initially presses against the tensioning beam 4. At this point, the tensioning beam 4 contacts the slurry retaining plate 7, blocking both ends of the sleeper mold 6.

[0108] Afterwards, the prestressed steel wires 10 are further tensioned by the piston rods 1013. During the tensioning process, each prestressed steel wire 10 has different curvatures. Under the same tensioning force, when the prestressed steel wires 10 are initially straightened, their tensioned ends ultimately land in different positions. Each prestressed steel wire 10 corresponds to a separate piston rod 1013 to accommodate this situation. The presence of the common oil injection chamber 1014 and the common oil return chamber 1015 ensures that the tensioning force of each piston rod 1013 is the same. After tensioning is complete, all prestressed steel wires 10 are subjected to the same tensioning force.

[0109] After the tensioning is completed, the tensioning positioning operation begins. The locking motor 301 is started, so that it drives the locking gear 302 to rotate to a meshing position with the nut gear 201, and drives the nut gear 201 to rotate together. Because the tensioning rod 2 is tightly pulled by the tensioning force and cannot rotate, the nut gear 201 will move forward axially along the tensioning rod 2 while rotating until it presses against the tensioning beam 4, completing the tensioning positioning. At this time, the tensioning beam 4 further presses against the second tensioning portion 5022, that is, the second tensioning portion 5022 completes the further pressure on the tensioning beam 4. It should be noted here that the axial thickness of the nut gear 201 or the locking gear 302 must ensure that there is sufficient meshing time between the nut gear 201 and the locking gear 302 to prevent the nut gear 201 from disengaging from the locking gear 302 before pressing against the tensioning beam 4, so as to ensure that the nut gear 201 can be smoothly moved to the position pressing against the tensioning beam 4.

[0110] Furthermore, locking gear 302 is a half-gear structure. This half-gear structure can be half the size of a full gear, meaning it can be cut along its diameter, splitting the full gear in half. Alternatively, this half-gear structure can be a quarter the size of a full gear, meaning it can be cut along two perpendicular diameters, dividing the full gear into four equal parts, with one of the four parts being taken. Alternatively, it can be a third, a fifth, or the like, of a full gear, depending on the needs.

[0111] The size of the half gear structure preferably satisfies the following condition: when the nut gear 201 reaches the position pressing against the tensioning beam 4, the locking gear 302 can just disengage from the nut gear 201, that is, the position shown in FIG. 26 .

[0112] After tensioning and positioning, the "tensioning control device" can be removed so that it can tension another set of prestressed steel wires 10. Specifically, the "tensioning control device" is moved in the transverse X direction so that the clamping head 203 of the tensioning rod 2 can be removed from the tensioning rod connector 102 through the notch 104.

[0113] The sleeper mold 6 that has previously completed tensioning the prestressed steel wire 10 can then complete subsequent grouting and other procedures. When the sleeper grouting and other procedures are completed and the prestressing force needs to be released, the driving bolt 505 is rotated in the opposite direction, causing the driving bolt 505 to move upward, thereby causing the second tensioning portion 5022 to release the pressure on the tensioning beam 4, thus releasing the tensioning force.

[0114] It should be noted here that before the locking gear 302 engages with the nut gear 201, its initial position is away from the nut gear 201. For example: referring to Figure 5, if the tensioning rod connector 102 is located below the gear shaft 305, the locking gear 302 of the half-gear structure rotates to the top of the gear shaft 305 as the initial position; if the tensioning rod connector 102 is located above the gear shaft 305, the locking gear 302 of the half-gear structure rotates to the bottom of the gear shaft 305 as the initial position; if the tensioning rod connector 102 is located on one side of the gear shaft 305, the locking gear 302 of the half-gear structure rotates to the other side of the gear shaft 305 as the initial position. When starting to work, each locking gear 302 rotates and engages the nut gear 201 to rotate, so that the nut gear 201 presses against the tensioning beam 4, and then rotates back to the initial position, completing a locking cycle. Afterwards, when the "tensioning control device" is removed, the locking gear 302 will not contact or scrape the nut gear 201, so that the "tensioning control device" can be removed smoothly.

[0115] The "tensioning control device" is moved as a whole by means of a movable mounting frame 9, achieving convenient and efficient operation. The overall movement of the movable mounting frame 9 can utilize existing mobile technologies such as a mobile trolley. Furthermore, for the movable mounting frame 9, an optional limit plate 18 extending forward in the longitudinal Y direction is provided at the front end of the rectangular frame 901. Two limit plates 18 are provided, one on each side of the rectangular frame 901 along the longitudinal Y direction. Components such as the locking module 3 and the tensioning rod connector 102 are located between the two limit plates 18. The two limit plates 18 are parallel to the tensioning rod connector 102 and extend forward the same distance. The limiting top plate 18 can be directly welded to the mounting plate 902, or it can be fixed to the front end of the rectangular frame 901 via a fastening plate 19, with the upper portion of the fastening plate 19 fixedly connected to the upper rectangular frame 9011, and the lower portion of the fastening plate 19 fixedly connected to the lower rectangular frame 9012. Using fastening plates 19 can reduce the load on the mounting plate 902, reduce the risk of damage to the mounting plate 902, and improve the operational stability of the "tensioning control device." The limiting top plates 18 function as follows: Function 1: When in use, the two limiting top plates 18 can press against the tensioning beam 4, achieving relative fixation between the movable mounting frame 9 and the sleeper mold 6, allowing the piston rod 1013 to smoothly pull the prestressed steel wire 10. Of course, the relative fixation between the movable mounting frame 9 and the sleeper mold 6 can also be achieved using any other known and feasible method. Function 2: The two limiting top plates 18 are parallel and have the same extension length, which can ensure the stability of the tensioning trajectory during the tensioning process of the piston rod 1013 and prevent the phenomenon of being pulled crooked. It should be noted here that in this form, when in use, the movable mounting frame 9 is first moved to the two ends of the sleeper mold 6 along the longitudinal Y direction, so that the tensioning rod 2 corresponds to the notch 104 of the tensioning rod connector 102, and then the movable mounting frame 9 is moved along the transverse X direction, so that the clamping head 203 of the tensioning rod 2 is placed into the tensioning rod connector 102 from the notch 104, and then the movable mounting frame 9 is moved along the longitudinal Y direction and the two limiting top plates 18 are brought into contact with the tensioning beam 4, so that the two limiting top plates 18 can be pressed against the tensioning beam 4 during the tensioning process.

[0116] In summary, the tensioning force control device for prestressed sleepers of the present invention solves the problems existing in the prior art very well. It adopts an integrated multi-cylinder synchronous hydraulic oil cylinder as a tensioning jack, which can tension the prestressed steel wires separately, thereby avoiding the synchronous movement of the tensioning ends of multiple prestressed steel wires. At the same time, multiple piston rods can also synchronously supply and return oil, so that the tension applied by each piston rod on its corresponding prestressed steel wire remains consistent, greatly reducing the phenomenon of excessive prestress deviation between multiple steel wires, avoiding the phenomenon of longitudinal cracks at the ends of the sleepers caused by excessive prestress deviation, and improving the production quality and service life of the sleepers. In addition, the locking module in the present invention saves time and effort in tensioning and positioning, greatly improving construction efficiency.

[0117] In the description of the present invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be understood to indicate or imply relative importance or implicitly specify the number of the technical features indicated. Therefore, a feature specified as "first" or "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, "plurality" means two or more, unless otherwise specifically defined.

[0118] In the present invention, unless otherwise clearly specified and limited, the terms "installation" and "fixing" should be understood in a broad sense. For ordinary technicians in this field, they can understand the specific meanings of the above terms in the present invention according to specific circumstances.

[0119] In the description of this specification, the description of the term "embodiment" or the like 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 present invention. 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 mutually inconsistent.

[0120] Although the embodiments of the present invention have been shown and described above, it will be understood that the above embodiments are illustrative and are not to be construed as limitations on the present invention. A person skilled in the art may alter, modify, replace and modify the above embodiments within the scope of the present invention.

Claims

1. A prestressed sleeper tension control device, characterized in that: It comprises a tensioning module (1), a tensioning rod (2) and a locking module (3); The tensioning module (1) comprises a tensioning jack (101) and a tensioning rod connector (102); the tensioning jack (101) comprises a plurality of cylinder bodies (1012) provided with piston rods (1013); the oil injection chambers (10121) of the plurality of cylinder bodies (1012) are connected to each other and the oil return chambers (10122) are also connected to each other; the piston rod (1013) is connected to the tensioning rod connector (102); the tensioning rod connector (102) is temporarily connected to the rear end of the tensioning rod (2) when in use; The outer wall of the tension rod (2) is sleeved with a nut gear (201), and the nut gear (201) is threadedly matched with the outer wall of the tension rod (2); a tensioning stepped hole (202) is provided inside the tension rod (2); The locking module (3) comprises a locking motor (301) and a locking gear (302); the output end of the locking motor (301) is connected to the locking gear (302); the locking gear (302) meshes with the nut gear (201) when in use; The tension rod connector (102) is provided with a connection step hole (103) inside; a notch (104) for the tension rod (2) to pass through is provided on the side of the connection step hole (103); The rear end of the tension rod (2) is provided with a clamping head (203) for clamping in the connecting stepped hole (103); The locking gear (302) is a half gear structure; It also includes a tensioning crossbeam (4) located at the end of the sleeper mold (6); when in use, the tensioning crossbeam (4) is located at the front end of the tensioning rod (2) for the nut gear (201) to press against; the tensioning crossbeam (4) is provided with a working through hole (401) for the prestressed steel wire (10) to pass through; It also includes a sheet placing module (5); the sheet placing module (5) includes a sheet placing shell (501), a sheet placing portion (502) and a sheet placing wedge (503); An opening (504) is provided on one side of the sheet-releasing shell (501); the sheet-releasing portion (502) is located in the sheet-releasing shell (501); the sheet-releasing portion (502) includes a first sheet-releasing portion (5021) and a second sheet-releasing portion (5022); a V-shaped groove is formed between the first sheet-releasing portion (5021) and the second sheet-releasing portion (5022); the sheet-releasing wedge (503) extends into the V-shaped groove. The second tensioning portion (5022) is moved in the groove and can move relative to the V-shaped groove to force the second tensioning portion (5022) to extend out of the opening (504); the second tensioning portion (5022) is pressed to move by moving the tensioning wedge (503), and the second tensioning portion (5022) can be translated and extend out of the opening (504) to press against the tensioning beam (4); The tensioning jack (101) comprises a main body (1011); a plurality of cylinder bodies (1012) are provided on the main body (1011), and a piston rod (1013) is provided in each of the cylinder bodies (1012); a common oil injection chamber (1014) is provided at one end of the main body (1011), and is communicated with the oil injection chamber (10121) of each of the cylinder bodies (1012); and a common oil return chamber (1015) is provided at the other end of the main body (1011), and is communicated with the oil return chamber (10122) of each of the cylinder bodies (1012).

2. A prestressed sleeper tension control device as claimed in claim 1, characterized in that: The tensioning module (1) and the locking module (3) are both arranged on a movable mounting frame (9).

3. A prestressed sleeper tension control device according to claim 1, characterized in that: The release module (5) further comprises a driving unit; the driving unit comprises a driving bolt (505) and a driving bracket (506); the driving bracket (506) is located at the top of the release housing (501); the driving bolt (505) passes through the driving bracket (506) and is connected to the top end of the release wedge (503); the driving bolt (505) is threadedly connected to the driving bracket (506).

4. A prestressed sleeper tension control device as claimed in claim 3, characterized in that: The sheet placing module (5) further comprises a vertical guide rail (507) and an electric wrench (508); the vertical guide rail (507) is located on one side of the sheet placing housing (501); the electric wrench (508) is arranged on the vertical guide rail (507) and can move along the vertical guide rail (507); the electric wrench (508) is engaged with the nut (5051) at the top of the driving bolt (505).

5. A prestressed sleeper tension control device as claimed in claim 1, characterized in that: A slurry-blocking plate (7) is arranged in front of the tensioning crossbeam (4); and a slurry-blocking rubber ring (8) is arranged between the tensioning crossbeam (4) and the slurry-blocking plate (7).

Images