Automatic production system for prefabricated sleepers

Abstract

The present invention discloses an automatic production system for prefabricated rail sleepers, including an embedded part manufacturing and installation station, a concrete pouring station, a curing and molding station, and a demoulding and stacking station. The curing and molding station is located between the concrete pouring station and the demoulding and stacking station. The embedded part manufacturing and installation station includes an iron embedded section, a steel embedded section, and a steel tensioning section that are in the same straight line and are all equipped with a rotating roller group. The concrete pouring station includes a concrete to-be-cast section, a concrete pouring section, and a concrete vibrating and smoothing section that are in the same straight line and are all equipped with a rotating roller group. The demoulding and stacking station includes a finished product temporary storage section and a demoulding agent spraying section. The demoulding agent spraying section is adjacent to the iron embedded section, and a rotating roller group is also installed below the demoulding agent spraying section and is in the same straight line with the iron embedded section. Through the above-mentioned arrangement, the stations are arranged neatly and orderly, the production space is arranged reasonably, a complete circulation production flow is formed, space occupation is reduced, and production efficiency is improved.

Description

Technical Field

[0001] The invention relates to the field of sleeper production, and in particular to an automatic production system for prefabricated sleepers. Background Art

[0002] Sleepers are an indispensable basic structure in railway transportation. China's railway construction and urban light rail transportation have been developing rapidly in recent years, which naturally also promoted the development of sleeper manufacturing field. From the initial wooden sleepers to cast-in-place concrete sleepers, to the more common prefabricated prestressed concrete sleepers, the quality and output have been steadily improved.

[0003] A Chinese patent application with application number CN201310054478.8 discloses a double-block sleeper production line, which includes a vibrating table. The vibrating table is provided with a material placing machine that can slide left and right along a slide rail. A lifting track is provided on the left side of the vibrating table and between the slide rails. A first mold chain conveyor vertically connected to the slide rail is provided on the side of the lifting track. A conveying track is provided on the right side of the vibrating table. A tipping platform is provided above the middle of the conveying track. A second mold chain conveyor is provided at the right end of the conveying track. An automatic aerial mold tipping machine is provided on the second mold chain conveyor. The free ends of the first mold chain conveyor and the second mold chain conveyor are connected by an automatic stacker. A sleeper output device is provided on the right side of the conveying track.

[0004] However, the production line is not complete. It is impossible to carry out one-way production in actual production. Especially for the production of sleepers, the molds must be circulated. Therefore, the design of the production line needs to be further improved. Summary of the invention

[0005] In view of the deficiencies in the prior art, the object of the present invention is to provide an automatic production system for prefabricated sleepers, in which each workstation is connected in an orderly manner, the installation is compact, the overall space occupied is reasonable, and the production efficiency is high.

[0006] The above technical purpose of the present invention is achieved through the following technical solutions: an automatic production system for prefabricated sleepers, including an embedded part manufacturing and installation station, a concrete pouring station, a curing and molding station, and a demolding and stacking station. The curing and molding station is located between the concrete pouring station and the demolding and stacking station. The embedded part manufacturing and installation station includes an iron embedded section, a steel embedded section and a steel tensioning section that are in the same straight line and are all equipped with a rotating roller group. The concrete pouring station includes a concrete to-be-cast section, a concrete pouring section and a concrete vibration and leveling section that are in the same straight line and are all equipped with a rotating roller group. The demolding and stacking station includes a finished product temporary storage section and a release agent spraying section. The release agent spraying section is adjacent to the iron embedded section, and a rotating roller group is also installed below the release agent spraying section and is in the same straight line as the iron embedded section.

[0007] By adopting the above technical solution, the workstations are arranged neatly and orderly, the production space is arranged reasonably, forming a complete circular production flow, reducing space occupancy and improving production efficiency.

[0008] The present invention is further configured as follows: the demoulding and stacking station also includes a demoulding and cutting section arranged in parallel with the finished product temporary placement section, a mold cleaning section which is in the same straight line as the finished product temporary placement section and arranged in parallel with the release agent spraying section, a mold turning machine is installed between the finished product temporary placement section and the demoulding and cutting section, and a stacking machine is installed at the end of the demoulding and cutting section.

[0009] By adopting the above technical solution, the sleeper is transported to the temporary storage section for finished products after being formed in the mold, and is flipped to the demolding and cutting section by the mold flipping machine for demolding, so that the mold and the sleeper product are separated. The product is stacked and transported out through the stacking machine, and the mold enters the mold cleaning section for cleaning and put into the next production.

[0010] The present invention is further configured as follows: a translation frame is installed between the mold cleaning section and the release agent spraying section, the mold placed on the mold cleaning section is translated to the release agent spraying section through the translation frame, and the rotating roller groups installed in the release agent spraying section, the iron pre-embedded section, the steel bar pre-embedded section and the steel bar tensioning section are multiple groups of rotating roller groups on a straight line, which are used for linear sliding transportation of the mold.

[0011] By adopting the above technical solution, setting up a suitable translation frame can make full use of the width space of the factory building. At the same time, the rotating roller groups installed in the release agent spraying section, the iron pre-embedded section, the steel bar pre-embedded section and the steel bar tensioning section are multiple groups of rotating roller groups on a straight line, which are used for the linear sliding transportation of the mold. Therefore, the cleaned mold can be officially put into the next production after spraying the release agent.

[0012] The present invention is further configured as follows: a translation frame is also installed between the steel bar tensioning section and the concrete to be poured section, and the mold placed on the steel bar tensioning section is translated to the concrete to be poured section through the translation frame.

[0013] By adopting the above technical solution, a translation frame is also installed between the steel bar tensioning section and the concrete pouring section, which not only can utilize the width space of the factory building, but also is necessary to shorten the installation length of the entire production line so that the arrangement between the workstations is within a reasonable range.

[0014] The present invention is further configured as follows: the embedded parts manufacturing and installation station also includes a stretch-forming chute for the steel bar grouping, the stretch-forming chute is arranged parallel to the steel bar embedded section, and a steel bar placement rack is arranged between the two, one end of the stretch-forming chute is connected to an operating platform, and the other end is connected to a winch, and one side of the operating platform is connected to a pier head machine.

[0015] By adopting the above technical scheme, the steel bar grouping process is orderly and neat, the steel bar grouping efficiency is higher, the error rate is reduced, and the labor intensity is reduced. Setting a reasonable position relationship is conducive to improving the efficiency of process connection between each step. The steel bars after unloading are inserted into the end partition and the pier head plate on the operating platform. After the pier head is completed, the steel bar group can be placed on the expansion forming slide, and the expansion and stretching of the steel bar group can be achieved by the winch.

[0016] The present invention is further configured as follows: the upper end of the expansion-forming slide is open and a fixed plate is slidably inserted therein, the fixed plate includes a horizontal slide slidably inserted in the expansion-forming slide, and at least one pair of abutment protrusions fixedly connected to the horizontal slide, and the width of the abutment protrusions is smaller than the spacing between the steel bars in a group of steel bars, and the height of the abutment protrusions is greater than two-thirds of the height of the end partitions installed at both ends of a group of steel bars.

[0017] By adopting the above technical solution, the horizontal slide plate can slide back and forth along the expansion-forming slide groove driven by the winch, and due to the setting of the abutment protrusion, the end partitions interspersed in the steel bar group can be abutted and driven to slide synchronously, thereby stretching the entire steel bar group into shape.

[0018] The present invention is further configured as follows: a pulley is connected to the expansion-formed chute, the pulley is located on the side wall of the expansion-formed chute at one end away from the winch, a steel wire rope is wound on the winch, one end of the steel wire rope is fixedly connected to a side of the horizontal slide close to the winch, and the other end of the steel wire rope slides through the expansion-formed chute and is fixedly connected to the other side of the horizontal slide after passing through the pulley.

[0019] By adopting the above technical solution, the wire rope is reeled in when the winch rotates, thereby driving the horizontal slide plate to slide along the slide groove. Similarly, when the winch rotates in the reverse direction, the wire rope can also be reeled in in the reverse direction, thereby driving the horizontal slide plate to slide in the reverse direction along the slide groove to achieve a reset effect.

[0020] The present invention is further configured as follows: at least two vertically arranged positioning protrusions are fixed to one end of the expansion-shaped slide groove abutting against the operating platform, and the width of the positioning protrusions is smaller than the spacing between steel bars in a group of steel bars.

[0021] By adopting the above technical solution, setting the positioning protrusion can prevent the winch from over-pulling. When placing the steel bar group, the last end partition or pier head plate can be placed at the tail of the steel bar group. When the winch starts to pull the horizontal slide plate to slide, the last end partition or pier head plate will eventually abut against the positioning protrusion as the entire steel bar group moves. At this time, the stretching of the entire steel bar group is completed, that is, the steel bar grouping operation is completed. At the same time, in the process of the winch pulling the entire group of steel bars to stretch, the positioning protrusion can timely comb and separate multiple steel bars to avoid the staggered knotting of multiple steel bars.

[0022] The present invention is further configured as follows: it also includes a gantry crane, and the width of the gantry crane is greater than or equal to the distance between the finished product temporary storage section and the concrete vibrating and smoothing section.

[0023] By adopting the above technical solution, a gantry crane can be installed to operate the mold in and out of the steam pool, and can also temporarily replace some section operations, thereby improving the operational flexibility of the entire production.

[0024] The present invention is further configured as follows: a material discharge hopper is arranged above the concrete pouring section, and the material discharge hopper is connected to a concrete mixing station.

[0025] By adopting the above technical solution, the pouring of concrete needs to be coordinated with the production rhythm, so a mixing station needs to be built, preferably outside the factory.

[0026] In summary, the present invention has the following beneficial effects: the workstations are arranged neatly and orderly, the production space is arranged reasonably, a complete circulating production flow is formed, the space occupation is reduced, and the production efficiency is improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 This is a system diagram of this embodiment.

[0028] Figure 2 It is a schematic diagram of the structure when the reinforcement bar grouping is completed in this embodiment.

[0029] Figure 3 It is a schematic diagram of the structure of this embodiment after the steel bar group and the pier head machine are hidden.

[0030] Figure 4 yes Figure 3 Enlarged view of point A.

[0031] Figure 5 yes Figure 3 Enlarged view of point B.

[0032] Figure numerals: 1. Pre-embedded parts manufacturing and installation station; 101. Iron parts pre-embedded section; 102. Steel bar pre-embedded section; 103. Steel bar tensioning section; 2. Concrete pouring station; 201. Concrete section to be poured; 202. Concrete pouring section; 203. Concrete vibration and leveling section; 3. Curing and molding station; 4. Expansion and molding chute; 5. Fixed plate; 51. Horizontal slide plate; 52. Abutment protrusion; 61. Winch; 62. Wire rope; 63. Pulley; 7. Demoulding and stacking station; 701. Finished product temporary storage section; 702. Release agent spraying section; 703. Demoulding and cutting section; 704. Mold cleaning section; 8. Translation frame; 9. Steel bar placement frame; 10. Pier head machine; 11. Operating platform; 12. Positioning protrusion; 13. Unloading funnel; 14. Concrete mixing station; 15. Steel bar group. DETAILED DESCRIPTION

[0033] An automatic production system for prefabricated sleepers, such as Figure 1 As shown, it includes an embedded part manufacturing and installation station 1, a concrete pouring station 2, a curing and molding station 3, and a demoulding and stacking station 7. The curing and molding station 3 mainly includes a steam pool, and the steam pool is built at one end of the factory and is located between the concrete pouring station 2 and the demoulding and stacking station 7. The embedded part manufacturing and installation station 1 and the demoulding and stacking station 7 are generally arranged in a straight line, while the concrete pouring station 2 is arranged in another straight line, and the embedded part manufacturing and installation station 1, the demoulding and stacking station 7 and the concrete pouring station 2 are all arranged along the length direction of the factory.

[0034] The embedded parts manufacturing and installation station 1 comprises an iron embedded section 101, a steel embedded section 102 and a steel tensioning section 103 which are in the same straight line and are all equipped with a rotating roller group, and also comprises a stretching forming chute 4 for steel bar grouping.

[0035] The iron embedded section 101 includes a set of rotating roller groups fixedly installed on the ground and multiple lifting cylinders. After the mold is placed on the rotating roller group, multiple lifting cylinders are started synchronously to lift up one side of the mold and flip it over. At this time, it is convenient for personnel to install and position the embedded sleeve from the bottom and side wall of the mold. After completion, the lifting cylinder returns to its position, and the rotating roller group starts and drives the mold to slide from the iron embedded section 101 into the steel bar embedded section 102.

[0036] like Figure 2 and 3 As shown, the expansion forming chute 4 is arranged in parallel with the embedded steel bar section 102, and a steel bar placement frame 9 is arranged between the two. One end of the expansion forming chute 4 is connected to an operating platform 11, and the other end is connected to a winch 61. One side of the operating platform 11 is connected to a pier head machine 10, and the operating platform 11 is also connected to a steel bar unloading area. After unloading, the steel bar is inserted into the end partition plate and the pier head plate on the operating platform 11. After the pier head is completed, the steel bar group 15 can be placed on the expansion forming chute 4, and the expansion and stretching of the steel bar group 15 can be achieved through the winch 61.

[0037] like Figure 4 and 5As shown, the upper end of the diastolic forming chute 4 is open and a fixed plate 5 is slidably inserted. The fixed plate 5 includes a horizontal slide 51 slidably inserted in the diastolic forming chute 4, and a pair of abutting protrusions 52 fixedly connected to the horizontal slide 51. The width of the abutting protrusions 52 is less than the spacing between the steel bars in a group of steel bars, and the height of the abutting protrusions 52 is greater than two-thirds of the height of the end partitions installed at both ends of a group of steel bars. A pulley 63 is connected to the diastolic forming chute 4. The pulley 63 is located on the side wall of the diastolic forming chute 4 at one end away from the winch 61. A steel wire rope 62 is wound on the winch 61. One end of the steel wire rope 62 is fixedly connected to the side of the horizontal slide 51 close to the winch 61. The other end of the steel wire rope 62 slides through the diastolic forming chute 4 and is fixedly connected to the other side of the horizontal slide 51 after being wound around the pulley 63.

[0038] like Figure 4 and 5 As shown, the horizontal slide plate 51 can slide back and forth along the expansion-molding chute 4 driven by the winch 61, and due to the setting of the abutting protrusion 52, the end partitions inserted in the steel bar group 15 can be abutted and driven to slide synchronously, thereby stretching the entire steel bar group 15. When the winch 61 rotates, the wire rope 62 is reeled in, thereby driving the horizontal slide plate 51 to slide along the chute. Similarly, when the winch 61 rotates in the reverse direction, the wire rope 62 can also be reeled in in the reverse direction, thereby driving the horizontal slide plate 51 to slide in the reverse direction along the chute, achieving the effect of resetting.

[0039] like Figure 4 and 5 As shown, at the same time, at least two vertically arranged positioning protrusions 12 are fixed to one end of the expansion forming chute 4 abutting against the operating platform 11, and the width of the positioning protrusion 12 is less than the spacing between the steel bars in a group of steel bars. The positioning protrusion 12 can prevent the winch 61 from pulling excessively. When placing the steel bar group 15, the last end partition or pier head plate can be placed at the tail of the steel bar group 15. When the winch 61 starts to pull the horizontal slide plate 51 to slide, the last end partition or pier head plate will eventually abut against the positioning protrusion 12 as the entire steel bar group 15 moves. At this time, the expansion of the entire steel bar group 15 is completed, that is, the steel bar grouping operation is completed. At the same time, in the process of the winch 61 pulling the entire group of steel bars to expand, the positioning protrusion 12 can timely comb and separate multiple steel bars to avoid multiple steel bars from being staggered and knotted.

[0040] like Figure 1 As shown, after completing the grouping of a group of steel bars, a group of steel bars can be placed on the steel bar placement rack 9. After the mold of the embedded iron section 101 is processed, a group of steel bars can be loaded into the mold placed on the embedded steel bar section 102, and the rotating roller group is started to drive the mold to the next steel bar tensioning station for prestressing of the steel bars.

[0041] The concrete pouring station 2 includes a concrete pouring section 201, a concrete pouring section 202 and a concrete vibrating and smoothing section 203, which are in the same straight line and are all equipped with a rotating roller group. A material discharge funnel 13 is arranged above the concrete pouring section 202, and the material discharge funnel 13 is connected to a concrete mixing station 14. A translation frame 8 is installed between the steel bar tensioning section 103 and the concrete pouring section 201, and the mold placed on the steel bar tensioning section 103 is translated to the concrete pouring section 201 through the translation frame 8. A gantry crane is also installed in the factory building, and the width of the gantry crane is slightly larger than the distance between the finished product temporary storage section 701 and the concrete vibrating and smoothing section 203. After the concrete enters the mold and is vibrated and smoothed, it is hoisted by the gantry crane to a steam pool for curing and molding.

[0042] After the sleepers are cured and formed, they are moved out by the gantry crane and enter the demoulding and stacking station 7. The demoulding and stacking station 7 includes a finished product temporary storage section 701, a demoulding and cutting section 703 arranged in parallel with the finished product temporary storage section 701, a demoulding agent spraying section 702, and a mold cleaning section 704 which is in the same straight line as the finished product temporary storage section 701 and arranged in parallel with the demoulding agent spraying section 702.

[0043] A mold turning machine is installed between the finished product temporary storage section 701 and the demoulding and cutting section 703, and a stacking machine is installed at the end of the demoulding and cutting section 703. After the sleeper is formed in the mold, it is transported to the finished product temporary storage section 701, and is buckled to the demoulding and cutting section 703 by the mold turning machine for demoulding, so that the mold and the sleeper product are separated, and the rotating roller group on the finished product temporary storage section 701 is started to transport the empty mold to the mold cleaning section 704, and the rotating roller group on the demoulding and cutting section 703 is started to transport the product sleeper to one end. During the transportation process, the steel bar cutting, end partition removal and labeling are carried out, and finally the product is stacked and transported out through the stacking machine.

[0044] The empty mold placed on the mold cleaning section 704 is cleaned by workers to clean the residual concrete. A translation frame 8 is installed between the mold cleaning section 704 and the release agent spraying section 702. The mold placed on the mold cleaning section 704 is translated to the release agent spraying section 702 through the translation frame 8. The release agent spraying section 702 is adjacent to the iron pre-embedded section 101, and a rotating roller group is also installed below the release agent spraying section 702 and is in the same straight line with the iron pre-embedded section 101. The rotating roller groups installed in the release agent spraying section 702, the iron pre-embedded section 101, the steel bar pre-embedded section 102 and the steel bar tensioning section 103 are multiple groups of rotating roller groups on a straight line, which are used for linear sliding transportation of the mold, thereby realizing a cyclic production operation.

Claims

1. An automatic production system for prefabricated sleepers, comprising an embedded part manufacturing and installation station (1), a concrete pouring station (2), a curing and molding station (3), and a demoulding and stacking station (7), wherein the curing and molding station (3) is located between the concrete pouring station (2) and the demoulding and stacking station (7), and is characterized in that: The embedded part manufacturing and installation station (1) comprises an iron embedded section (101), a steel embedded section (102) and a steel tensioning section (103) which are in the same straight line and are all equipped with a rotating roller group; the concrete pouring station (2) comprises a concrete to-be-poured section (201), a concrete pouring section (202) and a concrete vibrating and smoothing section (203) which are in the same straight line and are all equipped with a rotating roller group; the demoulding and stacking station (7) comprises a finished product temporary storage section (701) and a demoulding agent spraying section (702); the demoulding agent spraying section (702) is adjacent to the iron embedded section (101), and a rotating roller group is also installed below the demoulding agent spraying section (702) and is in the same straight line as the iron embedded section (101); The demoulding and stacking station (7) further comprises a demoulding and cutting section (703) arranged in parallel with the finished product temporary storage section (701), a mold cleaning section (704) which is in the same straight line as the finished product temporary storage section (701) and arranged in parallel with the mold release agent spraying section (702), a mold turning machine is installed between the finished product temporary storage section (701) and the demoulding and cutting section (703), and a stacking machine is installed at the end of the demoulding and cutting section (703); The embedded part manufacturing and installation station (1) also includes a stretch-forming chute (4) for steel bar grouping, the stretch-forming chute (4) is arranged in parallel with the steel bar embedded section (102), and a steel bar placement frame (9) is arranged between the two, one end of the stretch-forming chute (4) is connected to an operating platform (11), and the other end is connected to a winch (61), and one side of the operating platform (11) is connected to a pier head machine (10); The upper end of the expansion-shaped slide groove (4) is open and a fixed plate (5) is slidably inserted therein, and the fixed plate (5) comprises a horizontal slide plate (51) slidably inserted in the expansion-shaped slide groove (4), and at least one pair of abutment protrusions (52) fixedly connected to the horizontal slide plate (51), wherein the width of the abutment protrusions (52) is less than the spacing between steel bars in a group of steel bars, and the height of the abutment protrusions (52) is greater than two-thirds of the height of the end partitions installed at both ends of a group of steel bars.

2. The automatic production system for prefabricated sleepers according to claim 1 is characterized in that: A translation frame (8) is installed between the mold cleaning section (704) and the mold release agent spraying section (702); the mold placed on the mold cleaning section (704) is translated to the mold release agent spraying section (702) via the translation frame (8); and the rotating roller groups installed in the mold release agent spraying section (702), the iron pre-embedded section (101), the steel bar pre-embedded section (102) and the steel bar tensioning section (103) are multiple groups of rotating roller groups on a straight line, which are used for linear sliding transportation of the mold.

3. The automatic production system for prefabricated sleepers according to claim 2 is characterized in that: A translation frame (8) is also installed between the steel bar tensioning section (103) and the concrete to be poured section (201), and the mold placed on the steel bar tensioning section (103) is translated to the concrete to be poured section (201) through the translation frame (8).

4. The automatic production system for prefabricated sleepers according to claim 1 is characterized in that: A pulley (63) is connected inside the expansion-shaped chute (4), and the pulley (63) is located on the side wall of the expansion-shaped chute (4) away from the hoist (61). A steel wire rope (62) is wound on the hoist (61), and one end of the steel wire rope (62) is fixedly connected to a side of the horizontal slide plate (51) close to the hoist (61), and the other end of the steel wire rope (62) is slidably passed through the expansion-shaped chute (4) and is fixedly connected to the other side of the horizontal slide plate (51) after being wound around the pulley (63).

5. The automatic production system for prefabricated sleepers according to claim 4 is characterized in that: At least two vertically arranged positioning protrusions (12) are fixed to one end of the expansion-shaped slide groove (4) abutting against the operating platform (11), and the width of the positioning protrusions (12) is smaller than the spacing between steel bars in a group of steel bars.

6. The automatic production system for prefabricated sleepers according to claim 1 is characterized in that: It also includes a gantry crane, the width of which is greater than or equal to the distance between the finished product temporary storage section (701) and the concrete vibrating and smoothing section (203).

7. The automatic production system for prefabricated sleepers according to claim 1 is characterized in that: A material discharge hopper (13) is arranged above the concrete pouring section (202), and the material discharge hopper (13) is connected to a concrete mixing station (14).

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