CRTS I type double-block sleeper automated intelligent unmanned production line

Abstract

The present invention belongs to the technical field of automatic prefabrication of double-block sleepers, and specifically relates to an automatic intelligent unmanned production line for CRTS I-type double-block sleepers. Among them, a mold unstacking and demolding system, a mold residue cleaning system, a mold release agent spraying system, a pre-embedded sleeve and spiral rib installation system, a steel bar manufacturing and installation system, a precise concrete placing system, a mold hoisting and stacking system, and an intelligent curing system are sequentially connected to form a closed loop. The mold unstacking and demolding system is also sequentially connected to a double-block sleeper cleaning and capping system, a double-block sleeper stacking system, and a double-block sleeper intelligent buffer system. Each system is connected by a material automatic transportation system. The present invention is convenient to install and deploy, has a high turnover utilization rate and good use effect. While improving the production efficiency of sleepers and reducing the construction cost, it can also effectively avoid personnel injuries and potential safety hazards, eliminate the drawbacks of the mechanical + manual operation mode of double-block sleepers, and reduce pollution, achieving the purpose of energy conservation and emission reduction.

Description

Technical Field

[0001] The invention belongs to the technical field of automatic prefabrication of double-block sleepers, and specifically relates to an automatic intelligent unmanned production line for CRTS I-type double-block sleepers. Background Art

[0002] At present, the prefabrication production lines of double-block sleepers all adopt an operation mode combining machinery and pure manual labor for prefabrication tasks. To ensure that the prefabrication of double-block sleepers achieves automation, intelligence, and unmanned operation, each process and step of double-block sleepers adopts a manual + mechanical operation mode. The traditional production mode of double-block sleepers has problems such as a large investment in personnel, non-compliance with installation and cleaning requirements, high labor intensity, difficult quality control, large environmental pollution, major safety hazards, unsmooth operation of the production line, inaccurate data collection, etc., thus affecting the appearance quality of double-block sleeper finished products and the overall construction progress. In summary, due to the harms brought by the manual + mechanical operation mode; on the other hand, there are practical problems such as lagging product quality and construction progress. Summary of the Invention

[0003] In order to solve the above problems, the invention provides an automatic intelligent unmanned production line for CRTS I-type double-block sleepers.

[0004] The invention adopts the following technical solutions: An automatic intelligent unmanned production line for CRTS I-type double-block sleepers includes a mold residue cleaning system, a demoulding agent spraying system, a system for installing embedded sleeves and spiral bars, a steel bar manufacturing and installation system, a precise concrete placing system, a mold lifting and stacking system, an intelligent curing system, a mold unstacking and demoulding system, an intelligent inspection system for double-block sleepers, a cleaning and capping system for double-block sleepers, a stacking system for double-block sleepers, an automatic material transportation system, and an intelligent buffer system for double-block sleepers. Among them, the mold unstacking and demoulding system, the mold residue cleaning system, the demoulding agent spraying system, the system for installing embedded sleeves and spiral bars, the steel bar manufacturing and installation system, the precise concrete placing system, the mold lifting and stacking system, and the intelligent curing system are sequentially connected to form a closed loop. The mold unstacking and demoulding system is also sequentially connected to the cleaning and capping system for double-block sleepers, the stacking system for double-block sleepers, and the intelligent buffer system for double-block sleepers. Each system is connected through an automatic material transportation system.

[0005] The cleaning and capping system for double-block sleepers includes an industrial robot I, a vibrating disk, a 3D camera, a cleaning and capping tooling, a control electric box, and a conveyor belt I. The industrial robot I is arranged on both sides of the conveyor belt I. The cleaning and capping tooling is installed at the end of the industrial robot I. The vibrating disk is arranged beside the industrial robot I. The 3D camera is installed on the cleaning and capping tooling. The control electric box is equipped with a PLC controller for controlling the start, operation, and stop of the industrial robot, vibrating disk, 3D camera, and conveyor belt I. The cleaning and capping tooling includes a cleaning spray gun and a grasping suction cup. The 3D camera is arranged on one side of the grasping suction cup.

[0006] The vibrating bowl includes a vibrator and a rotating disk arranged on the vibrator. The center of the rotating disk is a slowly rotating cone. An upward spiral conveying channel with a width of a buckle cover is arranged on the inner wall of the rotating disk. The spiral conveying channel is divided into three layers from the bottom to the top. At the top of the second layer of the upper spiral conveying channel, a first horizontal baffle is arranged. The upper end of the first horizontal baffle is level with the third layer of the channel, and the bottom of the first horizontal baffle is at a thickness of a buckle cover from the plane of the second layer of the channel. A vertical baffle is arranged on one side of the third layer of the upper spiral conveying channel, and a second horizontal baffle is arranged at the outlet of the third layer. The bottom height of the second horizontal baffle is at a horizontal height of a buckle cover from the upper plane of the third layer of the channel.

[0007] The mold unstacking and demolding system includes an unstacking system arranged between the outlet of the steam curing channel and the demolding area and a demolding system arranged in the demolding area. The unstacking system includes a portal bracket I, a rail I, a cross beam, a lifting motor I, a rotating clamp, a locking device, and a pressing plate releasing device. Rails are arranged on both sides at the top of the portal bracket I. The cross beam is erected on the rail I. A lifting motor I that can move along the cross beam is arranged on the cross beam. The lifting motor I is connected to the rotating clamp through a steel wire rope. Locking devices are arranged at both ends of the rotating clamp, and a pressing plate releasing device is arranged at the central axis position of the rotating clamp.

[0008] The demolding system includes a translation truss, a demolding table, and a buffer bracket. The demolding table is arranged between the translation trusses, and the buffer bracket is arranged inside the demolding table.

[0009] The rotating clamp includes a hollow cross bar I. L-shaped steel members I are inserted into both ends of the cross bar I. The long sides of the L-shaped steel members I are inserted into the cross bar I and are connected to the cylinders inside it. The end of the short side of the L-shaped steel member I is hinged to the middle of the steel plate. Grooves are symmetrically arranged at both ends of the steel plate. A gear is installed at the central position on the upper side of the cross bar I, and the gear is driven by a motor.

[0010] The locking device includes a cylinder I installed on the lower side of the groove of the steel plate. The cylinder I is connected to a baffle. When the cylinder I retracts, the baffle is stuck at the outlet position of the groove.

[0011] The pressing plate releasing device includes a rotating frame arranged at the central position of the bottom of the cross bar. Both sides of the rotating frame are fixedly connected to a hook frame through cylinders II.

[0012] The translation truss includes a frame. The frame is a portal-shaped support. There is 1 steel frame on each of the left and right sides of the frame, and they are connected by 1 steel cross beam above. The frame is connected to the clamp through a vertical rod controlled by an oil cylinder. The clamp includes a hollow cross bar II. L-shaped steel members II are inserted into both ends of the cross bar of the clamp. The long sides of the L-shaped steel members II are inserted into the cross bar II and are connected to the cylinders inside it. The end of the short side of the L-shaped steel member II is hinged to the middle of the diamond-shaped steel plate. Round holes are symmetrically arranged at both ends of the diamond-shaped steel plate.

[0013] The demolding platform includes columns arranged on both sides. There is a demolding platform top plate arranged on the columns on both sides. An airbag is arranged on the lower side of the demolding platform top plate, and a bracket is arranged on the inner side of the column; the buffer bracket includes a support column, an arc-shaped elastic steel sheet is supported on the support column, and a horizontal support is installed on the arc-shaped elastic steel sheet.

[0014] The steel bar manufacturing and installation system includes a steel bar manufacturing system and a steel bar installation system. The steel bar manufacturing system includes a numerical control hoop bender, an industrial robot II, a grasping tooling, a welding platform, a conveyor belt II, and a welding machine. The numerical control hoop bender is independently arranged at one place. The conveyor belt II is arranged beside the numerical control hoop bender. The welding platform is arranged above the end of the conveyor belt II. There are two industrial robots II and they are symmetrically arranged on both sides of the conveyor belt II. A grasping tooling is installed at the end of one industrial robot II, and a welding machine is installed on the other industrial robot II and is arranged on the other side of the conveyor belt II.

[0015] The steel bar installation system includes a gantry bracket II, a fixture, a hook machine, a truss separation mechanism, a truss steel bar translation frame, and a steel bar assembly platform. The gantry bracket II is arranged outside the steel bar assembly platform. Tracks are arranged on both sides of the upper part of the gantry bracket II, and a fixture that can move along the tracks is installed on the tracks. The steel bar assembly platform is arranged below the gantry bracket II and is connected to the conveyor belt II; Hook machines are arranged on both sides of the steel bar assembly platform; the steel bar assembly platform and the truss separation mechanism are arranged in a staggered manner, and they are connected and transported by a truss steel bar translation frame in the middle.

[0016] On both sides of the bottom of the grasping tooling, a left groove and a right groove are respectively arranged. A movable groove is arranged between the left groove and the right groove. The end of the movable groove is connected to a cylinder, and the movement of the groove is realized through the expansion and contraction of the cylinder.

[0017] The welding platform is inclined. A pressing plate and a limiting block are arranged on the welding platform. One limiting block is arranged on the welding platform respectively in the up, down, left, and right directions. Among them, the upper, left, and right limiting blocks are fixed on the welding platform, and the lower limiting block is installed on a cylinder III.

[0018] The fixture includes a pressing plate rotating device, a steel bar pressing plate, a truss gripper, and a steel bar anti-drop top plate. The pressing plate rotating device is installed in the middle of the lower side of the fixture, and the pressing plate rotating device is installed at the center position inside the fixture. The steel bar pressing plate, the truss gripper, and the steel bar anti-drop top plate are arranged symmetrically about the center line. The steel bar anti-drop top plate is connected to the bottom of the fixture through a cylinder. There are two grooves arranged side by side at the bottom of the truss gripper.

[0019] The pressing plate rotating device includes a rotating frame arranged at the center of the bottom of the fixture. Both sides of the rotating frame are fixedly connected to a hook frame through a cylinder IV, and a perforation is arranged on the hook frame.

[0020] The truss separation mechanism includes a separation mechanism, a bracket, and a lifting cylinder. The lifting cylinder is installed in the middle of the bracket. The lower end of the lifting cylinder is connected to a long plate. Both ends of the long plate are connected to the separation mechanism through a central shaft. On both sides of the upper part of the separation mechanism, there are symmetrically arranged regular trapezoids. On both sides of the lower part of the separation mechanism, there are symmetrically arranged inverted trapezoids. The ends of the regular trapezoids and the inverted trapezoids are connected to telescopic cylinders.

[0021] The steel bar assembly platform includes a conveyor belt III, a top block, and a hook machine. Hook machines are arranged on both sides of the conveyor belt III. A top block is arranged below the conveyor belt III. A lifting oil cylinder is arranged at the bottom of the top block.

[0022] The concrete precise batching system includes an elevated ash transportation channel arranged between the mixing station and the concrete batching area of the production workshop. There is an elevated ash transportation trolley on the elevated ash transportation channel. In the concrete batching area, there is a portal bracket III. On both sides of the upper part of the portal bracket III, there are track II. A cross beam that can move along it is installed on the track II. A batching machine is installed on the lower side of the cross beam. A weighing hopper is installed at the position of the discharge port below the batching machine. A roller path is arranged below the portal bracket III. A double-block sleeper mold that can move along it is arranged on the roller path. A vibrating table fixed on the ground is arranged inside the roller path. The elevated ash transportation trolley includes a rectangular bracket and cylindrical rollers. Vertical rods are arranged at the front and rear ends of the rectangular bracket. Both ends of the cylindrical rollers are connected to the vertical rods by shafts. On both sides of the rectangular bracket, there are rollers driven by motors. The upper part of the weighing hopper is an inverted trapezoidal cuboid, and the lower part is a regular cuboid. A gate is arranged on the lower bottom surface of the weighing hopper. One side of the weighing hopper is connected to a gravity sensor. The batching machine includes a cube-shaped outer frame. Inside the outer frame, there is a rectangular body with an open top. Inside the rectangular body, there are two rotatable mixing screw rods. There are 8 outlets at the bottom of the rectangular body, and a gate is arranged at each outlet.

[0023] The mold hoisting and palletizing system includes a portal bracket arranged in the hoisting and palletizing area. On both sides of the top of the portal bracket IV, there are symmetrically arranged track III. A cross beam that can move along it is installed on the track III. Track IV is installed on the top of the cross beam. A lifting motor II that can move along it is installed on the track IV. There are rollers and motors at both ends of the cross beam and the lifting motor II. The cross beam and the lifting motor II are driven by motors to move on the track I and the track II respectively through the rollers. The lifting motor II is connected to a rotating gear through a steel wire rope. The top of the rotating gear is connected to a motor. A clamp is installed at the bottom of the rotating gear. The clamp includes a hollow cross bar. L-shaped steel members are inserted into both ends of the cross bar. The long sides of the L-shaped steel members are inserted into the cross bar and are connected to the cylinders inside it. The short sides of the L-shaped steel members are bifurcated structures, and hooks are respectively arranged at the ends of the bifurcated structures of the short sides.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. It has a simple structure, reasonable design, high turnover utilization rate, and is convenient for installation and layout.

[0026] 2. It is easy to operate and has a high degree of intelligence, reducing the time consumed at each workstation. The number of workers per shift has been reduced from the original 47 to 18 and finally to 0, improving the work efficiency index.

[0027] 3. The automated intelligent unmanned production line for double-block sleepers improves production efficiency and also enhances the construction stability of double-block sleepers.

[0028] 4. The automated intelligent unmanned production line does not require manual operation, avoiding personnel injuries and eliminating potential safety hazards.

[0029] 5. It has high practical value, reduces environmental pollution, and achieves the goal of energy conservation and emission reduction.

[0030] In summary, the present invention has a reasonable design, is convenient for installation and layout, has a high turnover utilization rate, and good usage effects. While improving the production efficiency of sleepers and reducing construction costs, it can also effectively avoid personnel injuries and potential safety hazards, eliminate the drawbacks of the mechanical + manual operation mode for double-block sleepers, and reduce pollution, achieving the goal of energy conservation and emission reduction. The technical solution of the present invention will be further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 is the actual flowchart of the production line of the present invention;

[0032] Figure 2 is the circulation flowchart of the double-block sleeper mold of the present invention;

[0033] Figure 3 is the production flowchart of the double-block sleeper of the present invention;

[0034] Figure 4 is the circuit control diagram of the present invention;

[0035] Figure 5 is the schematic diagram of the palletizing system provided by the present invention;

[0036] Figure 6 is the schematic diagram of the demoulding system provided by the present invention;

[0037] Figure 7 is the schematic diagram of the rotary fixture structure;

[0038] Figure 8 is the schematic diagram of the locking device structure;

[0039] Figure 9 is the schematic diagram of the pressing plate releasing device structure;

[0040] Figure 10 is the schematic diagram of the translation truss structure;

[0041] Figure 11 It is a schematic diagram of the demoulding platform structure;

[0042] Figure 12 It is a schematic diagram of the buffer support structure;

[0043] Figure 13 It is a schematic diagram of the stirrup welding provided by the present invention;

[0044] Figure 14 It is a schematic diagram of the steel bar installation system provided by the present invention;

[0045] Figure 15 It is a schematic diagram of the steel bar assembly platform provided by the present invention;

[0046] Figure 16 It is a schematic diagram of the grasping tooling provided by the present invention;

[0047] Figure 17 It is a schematic diagram of the welding platform provided by the present invention;

[0048] Figure 18 It is a schematic diagram of the fixture provided by the present invention;

[0049] Figure 19 It is a schematic diagram of the truss steel bar translation frame structure;

[0050] Figure 20 It is a schematic diagram of the pressing plate rotating device structure;

[0051] Figure 21 It is a schematic diagram of the truss separation mechanism;

[0052] Figure 22 It is a partial schematic diagram of the truss separation mechanism;

[0053] Figure 23 It is a schematic diagram of the precise batching system;

[0054] Figure 24 It is a schematic diagram of the vibration system;

[0055] Figure 25 It is a schematic diagram of the elevated ash transport trolley;

[0056] Figure 26 It is a schematic diagram of the weighing hopper;

[0057] Figure 27 It is a schematic diagram of the batching machine;

[0058] Figure 28 It is a schematic diagram of the structure of the lifting and palletizing system;

[0059] Figure 29 It is a schematic diagram of the fixture structure;

[0060] Figure 30 Schematic structural diagram of the cleaning and capping system

[0061] Figure 31 Schematic structural diagram of the cleaning and capping tooling

[0062] Figure 32 Top view of the vibrating bowl

[0063] Figure 33 Front view of the vibrating bowl Specific implementation mode

[0064] As Figure 1-4 shown, an automated intelligent unmanned production line for CRTS I type double-block sleepers includes a mold residue cleaning system 7, a release agent spraying system 8, an embedded sleeve and spiral rib installation system 9, a steel bar manufacturing and installation system 10, a concrete precise batching system 12, a mold hoisting and palletizing system 13, an intelligent curing system 14, a mold palletizing and demolding system 6, a double-block sleeper intelligent detection system 5, a double-block sleeper cleaning and capping system 4, a double-block sleeper palletizing system 3, a material automatic transportation system 2, and a double-block sleeper intelligent buffer system 1. Among them, the mold palletizing and demolding system 6, the mold residue cleaning system 7, the release agent spraying system 8, the embedded sleeve and spiral rib installation system 9, the steel bar manufacturing and installation system 10, the concrete precise batching system 12, the mold hoisting and palletizing system 13, and the intelligent curing system 14 are sequentially connected to form a closed loop. The mold palletizing and demolding system 6 is also sequentially connected to the double-block sleeper cleaning and capping system 4, the double-block sleeper palletizing system 3, and the double-block sleeper intelligent buffer system 1, and each system is connected through the material automatic transportation system 2.

[0065] The working process of the present invention is as follows: The double-block sleeper mold first enters the mold residue cleaning system. Through automatic mold grinding and cleaning and automatic adsorption cleaning of mold residues, dead skin, residues, rust, and ash skin at positions such as the inner sidewall, bottom, and grooves of the mold are ground and cleaned. After grinding, the residues in the mold are automatically sucked out at the residue automatic adsorption position and enter the mold release agent spraying station; after the mold enters the mold release agent spraying system, the spraying equipment is automatically started. The mold release agent is evenly sprayed on each surface of the inner cavity of the mold through a pipeline connecting a high-pressure nozzle from a storage tank. After the mold release agent spraying is completed, the mold automatically enters the pre-buried sleeve and spiral rib automatic installation station; the pre-buried sleeve is automatically placed on the assembly production line in a vibrating screening machine. The spiral rib is produced by a spiral machine and placed on the pre-buried sleeve on the assembly production line. The pre-buried sleeve and the spiral rib are assembled through a rotating device and placed on a feeding plate and transported to the installation position. The mold enters the pre-buried sleeve and spiral rib installation system and is automatically fixed. The automatic installation equipment automatically locates and identifies and grabs the sleeve, and then automatically installs the pre-buried sleeve and the spiral rib according to the program and the position of the positioning shaft in the mold. By combining the torque, the descending height, and the number of rotation circles, it is ensured that the pre-buried sleeve and the spiral rib are vertically and tightly installed at the specified position. After the pre-buried sleeve and the spiral rib in the mold are installed, the fixed state is released and it automatically enters the steel bar manufacturing and installation system; the sleeper steel bars are divided into stirrups and truss steel bars. The stirrups are bent and formed by a stirrup bending machine and then grabbed and placed at the automatic welding station for automatic welding. The welded stirrups slide onto a conveyor belt. The truss steel bars are produced by a numerically controlled integrated production line, and then the truss steel bars are placed at the sleeper steel bar assembly station. Each sleeper steel bar consists of 2 truss steel bars, 2 stirrups, and 8 stirrup connectors. The stirrups are sent to the specified position by the conveyor belt. The truss steel bars are above the stirrups. The stirrup connectors tie and connect the truss steel bars and the stirrups by binding wires. The assembled sleeper steel bars are clamped and placed in the specified limit groove of the fixed mold by an automatic transportation device. After being placed in the mold, the rotating pressing plate of the sleeper steel bar is rotated 90° to fix the sleeper steel bar and prevent the steel bar from sliding and displacing. After the sleeper steel bars are placed in sequence, the fixed state is released, and the mold automatically moves into the concrete precise placing system; an elevated slideway is set up between the batching plant and the sleeper production workshop. The concrete is transported from the batching plant to the concrete placing station in the sleeper production workshop by an elevated ash transport trolley automatically walking on the elevated slideway. After the elevated ash transport trolley arrives, it is automatically placed in the placer. After the mold enters the concrete precise placing station, the concrete is placed in a weighing hopper by the placer. The concrete consumption per sleeper is set according to the mix ratio. After reaching the set weight, the feeding stops, and then the hopper opens to pour the concrete into the mold in layers while starting vibration to ensure that the concrete is uniform, dense, and bubble-free;After the pouring is completed, the mold moves to the lifting and palletizing station. After arriving, the lifting and palletizing system is automatically started by a signal. The palletizing machine positions and descends to clamp the mold. After clamping the mold, it lifts and rotates 90°. It automatically walks in front of the curing channel that is being opened. The mold senses that it is placed in place through gravity sensing, then releases the mold and returns to the standby position to wait for the next mold. During the lifting and palletizing process, the system automatically counts and detects the number of layers of the placed molds according to the descending height. After the mold is filled with 6 layers, the mold is automatically pushed into the curing channel by the pushing device; after the mold enters the curing channel, it starts the steam curing in four stages: static stop, temperature rise, constant temperature, and temperature drop. When a channel is filled with molds, the two side hatch doors automatically close, and the curing system automatically starts to control the curing effect of the double-block sleepers by setting the curing time, maximum temperature, and temperature rise rate in the system. When a curing cycle is completed, the hatch doors automatically open, and the mold enters the next station; the traction device pulls the mold out and transports it to the mold unstacking and demolding station. After the mold reaches the unstacking position, the system is automatically started. The unstacking machine positions and grabs the mold and releases the restriction of the rotating pressing plate on the steel bars, locks the two side lifting columns to prevent the mold from falling off. After the unstacking machine lifts the mold, it rotates 90° horizontally, walks above the demolding table, rotates 180° vertically during the descending placement process and is placed stably upside down on the demolding table. After releasing the mold restriction, the unstacking machine returns to the standby position to wait for the next mold. At the same time, the demolding system is automatically started for impact demolding. After the double-block sleepers are completely separated from the mold, the mold is lifted by the mold transporting truss and flipped 180° and placed on the production line roller path to enter the mold cleaning station. The mold completes a production cycle. The double-block sleepers are transported to the double-block sleeper inspection station by the sleeper transporting trolley. After the double-block sleepers arrive, the intelligent inspection system is automatically started to inspect the appearance and shape of the double-block sleepers respectively. The inspection data is fed back into the inspection system for intelligent identification to determine the inspection situation, and then the production date and inspection conclusion are marked. The system automatically sorts and collects the data for retention for later traceability; after the inspection is completed, it enters the cleaning and capping station. After entering the station, the cleaning and capping system is automatically started. First, it scans and positions through a camera, and then cleans and caps. After the cleaning and capping are completed, the double-block sleepers enter the palletizing station; after the double-block sleepers enter the palletizing position, the palletizing machine automatically rises to place the double-block sleepers in the palletizing position and sends a signal to the AGV trolley; the AGV trolley receives the signal, locates through the preset reflective columns, and then walks to the palletizing position to automatically transport a set of double-block sleepers to the buffer workshop. Another AGV trolley is responsible for the automatic transportation of steel bars and other materials. During the transportation process, the AGV trolley performs real-time positioning detection to prevent emergencies and ensure the safety of personnel and materials. The buffer workshop uses an ultrasonic atomizing humidifier for heat and humidity preservation. The sensor automatically detects the temperature and humidity in the workshop and controls it through the intelligent detection system to ensure the temperature and humidity in the workshop; the entire production line is centrally controlled and monitored by the central control system 11.;

[0066] Such as Figure 5 、 Figure 6As shown in the figure, a demounting and demoulding system for a double-block sleeper mould according to the present invention includes a double-block sleeper mould, a demounting system and a demoulding system. The demounting system is located between the outlet of the steam curing channel and the demoulding area for hoisting and transporting the double-block sleeper mould after steam curing to the demoulding area; the demoulding system is located within the demoulding area for separating the double-block sleeper mould from the double-block sleeper.

[0067] As Figure 5 Shown in the figure is the demounting system. The demounting system includes a gantry support 6.2, a rail 6.5, a cross beam 6.3, a lifting motor 6.4, a rotating clamp 6.7, a locking device 6.8 and a pressing plate releasing device 6.9. Rails 6.5 are arranged on both sides at the top of the gantry support 6.2. The cross beam 6.3 is erected on the rails 6.5. A lifting motor 6.4 that can move along the cross beam 6.3 is arranged on the cross beam 6.3. The lifting motor 6.4 is connected to the rotating clamp 6.7 by a steel wire rope. Locking devices 6.8 are arranged at both ends of the rotating clamp 6.7. A pressing plate releasing device 6.9 is arranged at the middle axis position of the rotating clamp 6.7. The gantry support is arranged between the outlet of the steam curing channel and the demoulding area, and its bottom is connected to the embedded parts in the ground to ensure its horizontal stability; the cross beam is erected on the gantry support to achieve longitudinal movement through the rails; the lifting motor is erected on the cross beam through the rails for lateral movement; the rotating clamp is formed by installing a rotating gear at the middle position of the top of the clamp and connecting them integrally to change the direction of the clamp, and the two arms of the rotating clamp can be telescoped to clamp and release the double-block sleeper mould; the lifting motor is connected to the rotating clamp by a steel wire rope, and the lifting of the rotating clamp is achieved through the lifting of the steel wire rope; the clamp locking device is installed at the groove at the end of the two arms of the rotating clamp, and the cooperation of the cylinder and the baffle realizes the fixation and release of the restriction on the double-block sleeper mould; the pressing plate releasing device is installed at the upper part of the inner middle axis of the clamp for releasing the fixation of the pressing plate on the truss reinforcement.

[0068] As Figure 6 Shown in the figure is the demoulding system. The demoulding system includes a translation truss 6.10, a demoulding table 6.11 and a buffer support 6.12. The demoulding table 6.11 is arranged between the translation trusses 6.10. The buffer support 6.12 is arranged inside the demoulding table 6.11. The double-block sleeper mould translation truss is arranged in the demoulding area and moves on a preset track for hoisting and transporting the double-block sleeper mould after separating the double-block sleeper from the double-block sleeper mould to the production line roller path; the demoulding table is arranged in the demoulding area and in the middle of the double-block sleeper mould transverse truss. The demoulding table is fixed to the ground by embedded parts. Air bags are installed at the four corners inside the demoulding table for lifting the double-block sleeper mould and then freely falling for impact demoulding operation; the buffer support is installed inside the demoulding table for buffering the self-weight and impact force when the double-block sleeper falls, reducing the collision and friction between the double-block sleeper and the double-block sleeper mould; the control box is placed beside, and a PLC controller is installed inside for controlling the start, operation and stop of each part of the demounting and demoulding system.

[0069] As shown Figure 7 in the figure, the rotary fixture 6.7 includes a hollow crossbar I 6.7.2. L-shaped steel members I 6.7.3 are inserted into both ends of the crossbar I 6.7.2. The long sides of the L-shaped steel members I 6.7.3 are inserted into the crossbar I 6.7.2 and connected to the internal cylinders therein. The ends of the short sides of the L-shaped steel members I 6.7.3 are hinged to the middle of the steel plate 6.7.4. Grooves are symmetrically arranged at both ends of the steel plate 6.7.4. A gear 6.7.1 is installed at the central position on the upper side of the crossbar I 6.7.2, and the gear 6.7.1 is driven by a motor. The steel plate can rotate around the connection point, and the L-shaped steel member I can control the telescopic movement of the long side according to the cylinder, so as to realize the clamping and loosening of the fixture; the gear is installed at the central position on the upper part of the crossbar I to drive the rotation of the fixture.

[0070] As shown Figure 8 in the figure, the locking device 6.8 includes a cylinder I 6.8.1 installed on the lower side of the groove of the steel plate 6.7.4. The cylinder I 6.8.1 is connected to the baffle 6.8.2. When the cylinder I 6.8.1 retracts, the baffle 6.8.2 is stuck at the outlet position of the groove. The cylinder is connected to the baffle, and the groove is closed by the telescopic movement of the cylinder, thereby restricting the mold from falling when it flips.

[0071] As shown Figure 9 in the figure, the pressing plate releasing device 9 includes a rotating frame 6.9.1 arranged at the central position of the bottom of the crossbar 6.7.2. Both sides of the rotating frame 6.9.1 are fixedly connected to the hook frame 6.9.3 through cylinders II 6.9.2. The clamping and loosening of the hook frame are controlled by the cylinders. The two ends of the pressing plate that restricts the steel bars on the mold can be hooked by the hook frame, and the pressing plate is rotated to release the restriction of the pressing plate on the steel bars.

[0072] As shown Figure 10 in the figure, the translation truss 6.10 includes a frame 6.10.1. The frame 6.10.1 is a bracket with a portal structure. There is one steel frame on each of the left and right sides of the frame 6.10.1, and they are connected by a steel cross beam above. The frame 6.10.1 is connected to the fixture through a vertical rod 6.10.2 controlled by an oil cylinder. The fixture includes a hollow crossbar II 6.10.3. L-shaped steel members II 6.10.4 are inserted into both ends of the fixture crossbar 6.10.3. The long sides of the L-shaped steel members II 6.10.4 are inserted into the crossbar II 6.10.3 and connected to the internal cylinders therein. The ends of the short sides of the L-shaped steel members II 6.10.4 are hinged to the middle of the diamond-shaped steel plate 6.10.5. Round holes are symmetrically arranged at both ends of the diamond-shaped steel plate 6.10.5. The fixture is connected to the frame through 4 vertical rods, and the lifting of the fixture is realized through the control of the oil cylinder. The translation truss lifts the fixture to the position of the mold, the round holes on the diamond-shaped steel plate of the fixture are aligned with the lifting columns of the mold, and the mold is clamped and lifted to realize the flipping and translation of the mold.

[0073] As shown Figure 10 and 11As shown in the figure, the demoulding platform 6.11 includes columns 6.11.1 arranged on both sides. A demoulding platform top plate 6.11.4 is arranged on the columns 6.11.1 on both sides. An airbag 6.11.3 is arranged on the lower side of the demoulding platform top plate 6.11.4. A bracket 6.11.2 is arranged inside the columns 6.11.1. The airbag controls the lifting of the demoulding platform top plate through inflation and deflation, thereby realizing the lifting of the mould. The buffer support 6.12 includes a support column 6.12.1. An arc-shaped elastic steel sheet 6.12.2 is supported on the support column 6.12.1. A cross support 6.12.3 is installed on the arc-shaped elastic steel sheet 6.12.2. The column is installed at the outer arc top position of the arc-shaped elastic steel sheet. Both ends of the cross bar are connected to both ends of the arc-shaped elastic steel sheet. The support column is fixed on the ground. When the sleeper falls and presses down on the cross bar, the arc-shaped elastic steel plate deforms. By the restoration of the deformation of the arc-shaped elastic steel plate, a reaction force is applied to reduce the gravity of the sleeper, thereby reducing the collision and friction between the sleeper and the mould.

[0074] The working process is as follows: When the double-block sleeper mould completes steam curing and enters the specific position for palletizing and demoulding, the palletizing and demoulding system is started. The cross beam and the lifting motor move to the position directly above the double-block sleeper mould. The rotating fixture is in the loosened state. The rotating fixture descends to a position where the centers of the grooves at the ends of the two arms of the rotating fixture are at the same height as the center of the lifting column on the double-block sleeper mould. The rotating fixture clamps the double-block sleeper mould. The fixture locking device fixes the double-block sleeper mould to ensure that it will not fall off during the flipping of the double-block sleeper mould. The pressing plate releasing device installed at the middle position on the inner top of the fixture rotates the pressing plate installed in the middle of the double-block sleeper mould by 90 degrees to release the fixation of the pressing plate on the steel bars of the double-block sleeper. The clamped and fixed double-block sleeper mould is automatically lifted to a certain height by the lifting motor. The double-block sleeper mould rotates 90 degrees and then is transported to directly above the demoulding platform. The double-block sleeper mould slowly descends and is placed on the demoulding platform. While descending, the double-block sleeper mould is flipped and inverted on the demoulding platform. After it is placed stably, the fixture locking device is released. The rotating fixture rises and returns to the palletizing and hoisting position to hoist the next double-block sleeper mould. The airbags at the four corners of the demoulding platform are inflated simultaneously to lift the double-block sleeper mould to a certain height, ensuring that the lifting heights at the four corners are the same when lifting, and then the air supply is stopped to allow the double-block sleeper mould to fall freely. Relying on the impact of the self-gravity of the double-block sleeper, the double-block sleeper is separated from the double-block sleeper mould. The sensors on the demoulding platform detect whether all the double-block sleepers have fallen off. When all the double-block sleepers are separated and fallen off, the translation truss of the double-block sleeper mould walks to above the demoulding platform, clamps, flips, and transports the empty double-block sleeper mould to the production line roller path for the next cycle of production.

[0075] As Figure 12 、 13, as shown in Fig. 14, the steel bar manufacturing and installation system 10 includes a steel bar manufacturing system and a steel bar installation system. The steel bar manufacturing system includes a numerical control hoop bender 10.2, an industrial robot II 10.3, a gripping tool 10.4, a welding platform 10.6, a conveyor belt II 10.7, and a welding machine 10.5. The numerical control hoop bender 10.2 is independently set in one place, the conveyor belt II 10.7 is arranged beside the numerical control hoop bender 10.2, the welding platform 10.6 is set above the end of the conveyor belt II 10.7, there are two industrial robots II 10.3 which are symmetrically arranged on both sides of the conveyor belt II 10.7. A gripping tool 10.4 is installed at the end of one of the industrial robots II 10.3, and a welding machine 10.5 is installed on the other industrial robot II 10.3, which is arranged on the other side of the conveyor belt II 10.7.

[0076] The steel bar installation system includes a gantry support II 10.9, a fixture 10.10, a hook machine 10.12, a truss separation mechanism 10.14, a truss steel bar translation frame 10.13, and a steel bar assembly platform 10.11. The gantry support II 10.9 is set outside the steel bar assembly platform 10.11. Tracks are arranged on both sides of the upper part of the gantry support II 10.9, and a fixture 10.10 that can move along the tracks is installed on the tracks. The steel bar assembly platform 10.11 is set below the gantry support II 10.9 and is connected to the conveyor belt II 10.7; Hook machines are arranged on both sides of the steel bar assembly platform 10.11; The steel bar assembly platform 10.11 and the truss separation mechanism 10.14 are arranged in a staggered manner, and the two are connected and transported by a truss steel bar translation frame 10.13 in the middle.

[0077] On both sides of the bottom of the gripping tool 10.4, a left groove 10.4.1 and a right groove 10.4.2 are respectively arranged. A movable groove 10.4.3 is arranged between the left groove 10.4.1 and the right groove 10.4.2. The end of the movable groove 10.4.3 is connected to a cylinder, and the movement of the groove is realized by the telescopic cylinder.

[0078] The welding platform 10.6 is inclined. A pressing plate 10.6.1 and a limit stop 10.6.2 are arranged on the welding platform 10.6. There is one limit stop 10.6.2 arranged respectively up, down, left, and right along the welding platform 10.6. Among them, the limit stops 10.6.2 on the upper part, left side, and right side are fixed on the welding platform 10.6, and the limit stop 10.6.2 on the lower part is installed on a cylinder III 10.6.3.

[0079] The jig 10.10 includes a pressing plate rotating device 10.16, a steel bar pressing plate 10.18, a truss gripper 10.19, and a steel bar anti-falling top plate 10.20. The pressing plate rotating device 10.16 is installed in the middle of the lower side of the jig 10.10. The pressing plate rotating device 10.16 is installed at the center position inside the jig 10.10. The steel bar pressing plate 10.18, the truss gripper 10.19, and the steel bar anti-falling top plate 10.20 are arranged symmetrically about the center line. The steel bar anti-falling top plate 10.20 is connected to the bottom of the jig 10.10 through a cylinder. There are two grooves arranged side by side at the bottom of the truss gripper 10.19.

[0080] The pressing plate rotating device 10.16 includes a rotating frame 10.21 arranged at the center of the bottom of the jig 10.10. Both sides of the rotating frame 10.21 are fixedly connected to a hook frame 10.23 through a cylinder IV 10.22. A perforation is provided on the hook frame 10.23.

[0081] The truss separation mechanism 10.14 includes a separation mechanism 10.14.1, a bracket 10.14.2, and a lifting cylinder 10.14.3. The lifting cylinder 14.3 is installed in the middle of the bracket 10.14.2. The lower end of the lifting cylinder 10.14.3 is connected to a long plate 10.14.4. Both ends of the long plate 14.4 are connected to the separation mechanism 10.14.1 through a central shaft 10.14.5. Regular trapezoids 10.14.7 are symmetrically arranged on both sides of the upper part of the separation mechanism 10.14.1. Inverted trapezoids 10.14.8 are symmetrically arranged on both sides of the lower part of the separation mechanism 10.14.1. The ends of the regular trapezoids 10.14.7 and the inverted trapezoids 10.14.8 are connected to a telescopic cylinder 10.14.6; the lifting action is realized through the lifting cylinder; the bottom of the truss separation mechanism is a left-right symmetric structure. The upper part of the end of the separation mechanism is a regular trapezoid, and the two sides can be overlapped through the telescopic cylinder to lift the upper chord bars of the truss steel bars; the lower part of the end of the separation mechanism is an inverted trapezoid, and the lower chord bars of the truss steel bars can be lifted through the telescopic cylinder. The truss steel bars can be turned upside down by rotating 180° along the central shaft at the end of the separation mechanism.

[0082] The steel bar assembly platform 10.11 includes a conveyor belt III 10.11.1, a top block 10.11.2, and a hook bending machine 10.11.3. The hook bending machines 10.11.3 are arranged on both sides of the conveyor belt III 10.11.1. The top block 10.11.2 is arranged below the conveyor belt III 10.11.1. A lifting oil cylinder is arranged at the bottom of the top block 10.11.2. The hook bending machine uses low-carbon steel cold-drawn wire to bend a hook connecting piece with hooks at both ends on site and connects the stirrups and the truss steel bars together.

[0083] The working process is as follows: Cold-rolled steel bars of different models are fed, straightened, welded, sheared, and stacked by the truss steel bar numerical control production line. Then, a row of truss steel bars is transported to the truss separation mechanism. After separating two truss steel bars by the truss separation mechanism, they are flipped and placed side by side on the truss steel bar translation rack, and the truss steel bars are transported to the front of the steel bar assembly platform. At the same time, the numerical control hoop bender feeds, straightens, and bends the hoop into an unclosed shape. The industrial robot equipped with the installation and grasping tooling grabs the hoop and places it on the welding platform. The welding platform shapes it by extrusion and limitation. The industrial robot equipped with the electric welding machine locates the welding position of the hoop by setting coordinates and performs carbon dioxide shielded welding. After welding, the welding platform relaxes to let the hoop slide onto the conveyor belt, and it is transported by the conveyor belt to the designated position on the steel bar assembly platform. After two hoops reach the designated position, the bracket under the assembly platform rises to lift the hoops to a certain height. The fixture clamps two truss steel bars on the truss steel bar translation rack and transports them above the steel bar assembly platform. The hook bender bends hooks on the hoops and truss steel bars using cold-drawn steel bars, so that the hooks hook the hoops and truss steel bars. After the hooks are bent, the bracket under the assembly platform descends to the original position, making the hooks hook the hoops and truss steel bars respectively above and below, keeping the hoops hanging under the truss steel bars. The fixture clamps the assembled steel bars and raises them to a certain height, accurately translates them to directly above the corresponding inner cavity of the mold cavity through coordinate position positioning. After alignment, the fixture slowly descends and places the steel bars into the reserved groove in the mold cavity. After the fixture relaxes and presses down, the pressing plate rotating device clamps the middle pressing plate of the mold and rotates it 90 degrees to firmly press the truss steel bars, preventing the steel bars from floating and falling off due to the placement of the steel bar guiding cloth and vibration. After the in-mold installation is completed, the fixture returns above the steel bar assembly platform to wait for the next group of steel bar assembly and installation. After all the inner cavities in the mold are installed, the mold enters the next process.

[0084] As Figure 23 、 Figure 24 shown, a precise concrete placing system. The elevated ash transportation channel 12.1 is arranged between the mixing station and the concrete placing area of the production workshop. An elevated ash transportation trolley 2 is provided on the elevated ash transportation channel 12.1. A gantry support 12.3 is arranged in the concrete placing area. Rails 12.6 are arranged on both sides of the upper part of the gantry support 12.3. A cross beam 12.4 that can move along it is arranged on the rails 12.6. A placing machine 12.5 is installed on the lower side of the cross beam 12.4. A weighing hopper 12.7 is installed at the position of the discharge port under the placing machine 12.5. A roller way 12.9 is arranged under the gantry support 12.3. A double-block sleeper mold 12.8 that moves along it is arranged on the roller way 12.9. A vibrating table 12.11 fixed on the ground is arranged inside the roller way.

[0085] As Figure 25As shown in the figure, the elevated ash transport trolley 12.2 includes a rectangular bracket 12.12 and a cylindrical roller 12.13. Vertical rods are provided at the front and rear ends of the rectangular bracket 12.12, and both ends of the cylindrical roller 12.13 are axially connected to the vertical rods. Rollers driven by motors are provided on both sides of the rectangular bracket 12.12.

[0086] As Figure 26 shown in the figure, the upper part of the weighing hopper 12.7 is an inverted trapezoidal cuboid, and the lower part is a regular cuboid. A gate is provided on the lower bottom surface of the weighing hopper 12.7, and a gravity sensor 12.14 is connected to one side of the weighing hopper 12.7.

[0087] As Figure 27 shown in the figure, the distributor 12.5 includes a cube outer frame 12.15. A cuboid 12.16 with an open top is fixed inside the outer frame 12.15. Two rotatable mixing screw rods are provided inside the cuboid 12.16. There are 8 outlets at the bottom of the cuboid 12.16, and a gate is provided at each outlet.

[0088] As Figure 23 、 Figure 24 shown in the figure, the elevated ash transport passage is arranged between the mixing station and the distribution area. Rails are provided on its upper part, and the elevated ash transport trolley travels on the rails of the passage to transport concrete to the distribution area; a portal bracket is arranged in the concrete distribution area. Rails are longitudinally arranged on the portal bracket, and a cross beam moves longitudinally on it. The distributor is arranged on the cross beam and moves laterally on it to distribute the loaded concrete; a weighing hopper is arranged below the distributor to weigh the concrete; roller tracks are arranged at designated positions in the distribution area to transport the double-block sleeper molds; a vibrating table is arranged in the middle of the roller tracks and fixed on the ground to vibrate the double-block sleeper molds; a control box is arranged at one place to control the movement, stop, rotation and dumping of the elevated ash transport trolley, the movement of the distributor, and the opening and closing of the gate at the discharge port.

[0089] The working process is as follows: After the concrete is mixed by the mixing plant according to the mix ratio, it is discharged into the elevated ash transport trolley below the discharge opening. After receiving the concrete, the elevated ash transport trolley travels along the track to the concrete placing area. After reaching the set receiving position of the placer, it stops. The elevated ash transport trolley is designed in a cylindrical style. The cylinder rotates around the central axis to align the notch with the upper opening of the placer, and the concrete falls into the placer. The advanced ash transport trolley returns to the receiving position at the discharge opening of the mixing plant to wait for the next batch of mixed concrete. The precise placing system establishes a coordinate system based on the entire placing area, automatically locates the placing position, the placer travels above the placing position, and the roller table transports the double-block sleeper mold to the placing position, and the mold is placed on the vibrating table. The placer is provided with 8 discharge holes according to the characteristics of the 8 inner cavities of the 1×4 shaped steel formwork of the double-block sleeper. A weighing hopper is installed below it and is equipped with a gravity sensor. The system calculates the amount of concrete required for each inner cavity according to the mix ratio. The gates of the 8 discharge holes are opened simultaneously to discharge materials into the corresponding weighing hoppers below. The gravity sensor reflects the weight of the concrete in the weighing hopper. After reaching the specified value, the gates of the discharge holes of the placer are closed in sequence. After all the gates of the discharge openings of the placer are closed, the gate of the discharge opening of the weighing hopper is opened to discharge materials into the mold. The concrete is placed in a layered pouring method. First, 70% of the total amount of concrete is poured, and the vibrating table starts to vibrate. After the concrete is vibrated and compacted without obvious bubbles, the remaining concrete is poured. The vibrating table vibrates until the concrete is compacted and there are no bubbles, and then the vibration stops.

[0090] As Figure 28 , as shown in Figure 29, the mold lifting and stacking system 13 includes a gantry support 13.2 arranged in the lifting and stacking area. On both sides of the top of the gantry support IV13.2, track III13.7 is symmetrically arranged. A cross beam 13.3 that can move along it is installed on the track III13.7. Track IV13.8 is installed on the top of the cross beam 13.3. A lifting motor II13.4 that can move along it is installed on the track IV13.8. At both ends of the cross beam 13.3 and the lifting motor II13.4, rollers and motors are provided. The cross beam 13.3 and the lifting motor II13.4 are driven by motors to move the rollers on the track I13.7 and the track II13.8 respectively. The lifting motor II13.4 is connected to the rotating gear 13.5 through a steel wire rope. The top of the rotating gear 13.5 is connected to the motor, and a clamp 13.6 is installed at the bottom of the rotating gear 13.5; the clamp 13.6 includes a hollow cross bar 13.6.1. L-shaped steel members 13.6.2 are inserted into both ends of the cross bar 13.6.1. The long sides of the L-shaped steel members 13.6.2 are inserted into the cross bar 13.6.1 and are connected to the cylinders inside it. The short sides of the L-shaped steel members 13.6.2 are of a bifurcated structure, and hooks are respectively arranged at the ends of the bifurcated structures of the short sides.

[0091] Among them, the number of double-block sleeper molds 1 is 4. The 4 double-block sleeper molds 1 are arranged in parallel to form an integral double-block sleeper mold. The gantry support is laid in the hoisting and palletizing area and is connected through embedded parts to ensure the stability and horizontality of the gantry support; the cross beam is erected on the rails on the gantry support and moves longitudinally on the guide rails; the lifting motor is mounted on the cross beam rails and moves horizontally; the lifting motor is connected to the fixture through a steel wire rope to control the lifting of the fixture; the rotating gear is installed on the fixture to change the direction of the fixture; the hoisting and palletizing program is used to control the longitudinal movement and stop of the cross beam, the movement and stop of the lifting motor, the rotation and lifting of the fixture, and the telescoping of the fixture.

[0092] The working process of the present invention is as follows: When the double-block sleeper mold enters the hoisting and palletizing station, the sensor is automatically activated. The hoisting and palletizing program locates the double-block sleeper mold according to the set commands and position coordinates, controls the cross beam, the lifting motor, and the fixture to move directly above the double-block sleeper mold. The fixture is in the loose state. After arriving, the fixture groove descends to the position of the hoisting column of the double-block sleeper mold, and the fixture clamps and hooks the hoisting column of the double-block sleeper mold. Whether there is a double-block sleeper mold being lifted is detected through a gravity sensor, and according to the program setting, when there is a double-block sleeper mold for hoisting and palletizing, it is prevented that the fixture automatically or forcibly loosens and causes the double-block sleeper mold to fall. After the double-block sleeper mold is firmly hooked, it automatically rises to a certain height, and the rotating gear controls the fixture to rotate 90 degrees, and moves horizontally and longitudinally to the palletizing position in front of the steam curing chamber door at the same time. The double-block sleeper mold slowly descends. After the double-block sleeper mold is placed stably, the gravity sensor detects whether the double-block sleeper mold is placed smoothly. After the detection result is qualified, the fixture is allowed to be loosened. The number of palletizing layers is automatically counted according to the falling height. After reaching the set number of layers, the next pallet is palletized. After the fixture places the double-block sleeper mold, it automatically rises and then rotates the fixture back to the preparation position, waiting for the command of the next double-block sleeper mold.

[0093] As Figure 30 shown, a double-block sleeper cleaning and capping system, the double-block sleeper cleaning and capping system 4 includes an industrial robot I 4.1, a vibrating disk 4.3, a 3D camera 4.4, a cleaning and capping tooling 4.5, a control electrical box 4.6, and a conveyor belt I 4.7. The industrial robot I 4.1 is laid on both sides of the conveyor belt I 4.7, the cleaning and capping tooling 4.5 is installed at the end of the industrial robot I 4.1, the vibrating disk 4.3 is laid beside the industrial robot I 4.1, the 3D camera 4.4 is installed on the cleaning and capping tooling 4.5, and the control electrical box is equipped with a PLC controller for controlling the start, operation, and stop of the industrial robot, the vibrating disk, the 3D camera, and the conveyor belt I; as Figure 31 shown, the cleaning and capping tooling 4.5 includes a cleaning spray gun 4.5.1 and a grasping suction cup 4.5.2, and the 3D camera 4.4 is arranged on one side of the grasping suction cup 4.5.2. The industrial robot is an existing device, and the robot model is the iSNM0060 series of light-load industrial robots.

[0094] The industrial robots are respectively arranged on both sides of the conveyor belt. A three-dimensional coordinate system is established with the industrial robot as the origin, and the running route is set according to the process steps. The vibrating bowl is arranged at the rear of the industrial robot and is used to supply the plastic buckle covers of double-block sleepers for the industrial robot to grasp. The vibrating bowl is designed with three layers, and the buckle covers vibrate continuously along the inner wall of the vibrating bowl and are sent upward to ensure that the buckle covers are all in the upright state. The cleaning buckle cover tooling is installed at the end of the industrial robot and is used for cleaning the inside of the embedded sleeve and buckling the cover at the pipe orifice. The cleaning buckle cover tooling is a unique tooling customized according to the characteristics of cleaning the embedded sleeve and buckling the cover of the double-block sleeper. The 3D camera is installed on the cleaning buckle cover tooling and is used for scanning, positioning and detecting the double-block sleeper. The 3D camera identifies and locates the position of the embedded sleeve of the double-block sleeper based on the stereo image scanning and recognition technology. The conveyor belt is used to transport the double-block sleepers to the next working station. There is a PLC controller in the control electric box, which controls the start, operation and stop of the industrial robot, vibrating bowl, 3D camera, conveyor belt, etc. according to the set instructions.

[0095] As Figure 32 , 33 shown, the vibrating bowl 4.3 includes a vibrator 4.3.1 and a rotating disk 4.3.2 arranged on the vibrator 4.3.1. The center of the rotating disk 4.3.2 is a slowly rotating cone. An upward spiral transportation channel 4.3.3 with a width of one buckle cover is arranged on the inner wall of the rotating disk 4.3.2. The spiral transportation channel 4.3.3 is divided into three layers from the bottom to the top. A first horizontal baffle 4.3.4 is arranged at the top of the second layer of the upper spiral transportation channel 4.3.3. The upper end of the first horizontal baffle 4.3.4 is level with the third layer of the channel, and the bottom of the first horizontal baffle 4.3.4 is at a distance of the thickness of one buckle cover from the plane of the second layer of the channel; a vertical baffle 4.3.5 is arranged on one side of the third layer of the upper spiral transportation channel 4.3.3, and a second horizontal baffle 4.3.6 is arranged at the outlet of the third layer. The bottom height of the second horizontal baffle 4.3.6 is at a horizontal height of one buckle cover from the upper plane of the third layer of the channel.

[0096] The structures of the remaining systems are all those of published applications and will not be elaborated here.

Claims

1. An automated intelligent unmanned production line for CRTS I double-block sleepers, characterized in that: It includes a mold residue cleaning system (7), a release agent spraying system (8), a pre-embedded sleeve and spiral rib installation system (9), a steel bar manufacturing and installation system (10), a precise concrete placing system (12), a mold lifting and palletizing system (13), an intelligent curing system (14), a mold depalletizing and demolding system (6), a double-block sleeper intelligent detection system (5), a double-block sleeper cleaning and capping system (4), a double-block sleeper palletizing system (3), a material automatic transportation system (2), and a double-block sleeper intelligent buffer system (1). Among them, the mold depalletizing and demolding system (6), the mold residue cleaning system (7), the release agent spraying system (8), the pre-embedded sleeve and spiral rib installation system (9), the steel bar manufacturing and installation system (10), the precise concrete placing system (12), the mold lifting and palletizing system (13), and the intelligent curing system (14) are sequentially connected to form a closed loop. The mold depalletizing and demolding system (6) is also sequentially connected to the double-block sleeper cleaning and capping system (4), the double-block sleeper palletizing system (3), and the double-block sleeper intelligent buffer system (1). Each system is connected by the material automatic transportation system (2). The described mold depalletizing and demolding system (6) includes a depalletizing system arranged between the outlet of the steam curing channel and the demolding area and a demolding system arranged in the demolding area. The depalletizing system includes a gantry support I (6.2), a track I (6.5), a cross beam (6.3), a lifting motor I (6.4), a rotating fixture (6.7), a locking device (6.8), and a pressing plate releasing device (6.9). Tracks (6.5) are arranged on both sides of the top of the gantry support I (6.2). The cross beam (6.3) is erected on the track I (6.5). A lifting motor I (6.4) that can move along the cross beam (6.3) is arranged on the cross beam (6.3). The lifting motor I (6.4) is connected to the rotating fixture (6.7) through a steel wire rope. Locking devices (6.8) are arranged at both ends of the rotating fixture (6.7). A pressing plate releasing device (6.9) is arranged at the central axis position of the rotating fixture (6.7). The described demolding system includes a translation truss (6.10), a demolding table (6.11), and a buffer support (6.12). The demolding table (6.11) is arranged between the translation trusses (6.10). The buffer support (6.12) is arranged inside the demolding table (6.11). The rotating fixture (6.7) includes a hollow cross bar I (6.7.2). L-shaped steel members I (6.7.3) are inserted into both ends of the cross bar I (6.7.2). The long sides of the L-shaped steel members I (6.7.3) are inserted into the cross bar I (6.7.2) and are connected to the cylinders inside it. The end of the short side of the L-shaped steel member I (6.7.3) is hinged to the middle of the steel plate (6.7.4). Grooves are symmetrically arranged at both ends of the steel plate (6.7.4). A gear (6.7.1) is installed at the central position on the upper side of the cross bar I (6.7.2). The gear (6.7.1) is driven by a motor. The described locking device (6.8) includes a cylinder I (6.8.1) installed on the lower side of the groove of the steel plate (6.7.4). The cylinder I (6.8.1) is connected to a baffle plate (6.8.2). When the cylinder I (6.8.1) retracts, the baffle plate (6.8.2) is stuck at the position of the groove outlet; The described pressing plate releasing device (6.9) includes a rotating frame ( 6.9.1) provided at the center of the bottom of the cross bar (6.7.2). Both sides of the rotating frame (6.9.1) are fixedly connected to a hook frame (6.9.3) through cylinders II (6.9.2); The described translation truss (6.10) includes a frame (6.10.1). The frame (6.10.1) is a bracket with a portal structure. There is one steel frame on each of the left and right sides of the frame (6.10.1), and they are connected by a steel cross beam above. The frame (6.10.1) is connected to a fixture through a vertical rod (6.10.2) controlled by an oil cylinder. The fixture includes a hollow cross bar II (6.10.3). L-shaped steel members II (6.10.4) are inserted at both ends of the fixture cross bar (6.10.3). The long sides of the L-shaped steel members II (6.10.4) are inserted into the cross bar II (6.10.3) and are connected to the cylinders inside it. The end of the short side of the L-shaped steel member II (6.10.4) is hinged to the middle of a diamond-shaped steel plate (6.10.5). Circular holes are symmetrically arranged at both ends of the diamond-shaped steel plate (6.10.5); The described demoulding platform (6.11) includes columns (6.11.1) provided on both sides. A demoulding platform top plate (6.11.4) is provided on the columns (6.11.1) on both sides. An air bag (6.11.3) is provided on the lower side of the demoulding platform top plate (6.11.4). A bracket (6.11.2) is provided on the inner side of the column (6.11.1); The described buffer bracket (6.12) includes a pillar (6.12.1). An arc-shaped elastic steel sheet (6.12.2) is supported on the pillar (6.12.1). A cross support (6.12.3) is installed on the arc-shaped elastic steel sheet (6.12.2); The described steel bar manufacturing and installation system (10) includes a steel bar manufacturing system and a steel bar installation system. The described steel bar manufacturing system includes a numerical control hoop bender (10.2), an industrial robot II (10.3), a grasping tooling (10.4), a welding platform (10.6), a conveyor belt II (10.7) and a welding machine (10.5). The numerical control hoop bender (10.2) is independently set at one place. The conveyor belt II (10.7) is arranged beside the numerical control hoop bender (10.2). The welding platform (10.6) is arranged above the end of the conveyor belt II (10.7). There are two industrial robots II (10.3) and they are symmetrically arranged on both sides of the conveyor belt II (10.7). A grasping tooling (10.4) is installed at the end of one of the industrial robots II (10.3), and a welding machine (10.5) is installed on the other industrial robot II (10.3) and is arranged on the other side of the conveyor belt II (10.7); The steel bar installation system comprises a gantry support II (10.9), a clamp (10.10), a hook bending machine (10.12), a truss separation mechanism (10.14), a truss steel bar translation frame (10.13) and a steel bar assembly platform (10.11), wherein the gantry support (II10.9) is arranged outside the steel bar assembly platform (10.11), tracks are arranged on both sides of the upper part of the gantry support (II0.9), and clamps (10.10) that can move along the tracks are installed on the tracks, and the steel bar assembly platform (10.11) is arranged below the gantry support II (10.9) and connected to the conveyor belt II (10.7); hook bending machines are arranged on both sides of the steel bar assembly platform (10.11); the steel bar assembly platform (10.11) and the truss separation mechanism (10.14) are arranged in a staggered manner, and the two are connected and transported by a truss steel bar translation frame (10.13) in the middle; The clamp (10.10) comprises a pressure plate rotating device (10.16), a steel bar pressing plate (10.18), a truss gripper (10.19) and a steel bar anti-falling top plate (10.20); the pressure plate rotating device (10.16) is installed in the middle of the lower side of the clamp (10.10); the pressure plate rotating device (10.16) is installed at the inner center of the clamp (10.10); the steel bar pressing plate (10.18), the truss gripper (10.19) and the steel bar anti-falling top plate (10.20) are arranged symmetrically about the center line; the steel bar anti-falling top plate (10.20) is connected to the bottom of the clamp (10.10) through a cylinder; and two grooves arranged side by side are arranged at the bottom of the truss gripper (10.19); The truss separation mechanism (10.14) comprises a separation mechanism (10.14.1), a bracket (10.14.2) and a lifting cylinder (10.14.3); the lifting cylinder (14.3) is installed in the middle of the bracket (10.14.2); the lower end of the lifting cylinder (10.14.3) is connected to the long plate (10.14.4); the two ends of the long plate (14.4) are connected to the separation mechanism (10.14.1) through a central axis (10.14.5); upright trapezoids (10.14.7) are symmetrically arranged on both sides of the upper part of the separation mechanism (10.14.1); inverted trapezoids (10.14.8) are symmetrically arranged on both sides of the lower part of the separation mechanism (10.14.1); and the ends of the upright trapezoid (10.14.7) and the inverted trapezoid (10.14.8) are connected to the telescopic cylinder (10.14.6).

2. The automated intelligent unmanned production line for CRTS I double-block sleepers according to claim 1, wherein: The described double-block sleeper cleaning and capping system (4) includes an industrial robot I (4.1), a vibrating bowl (4.3), a 3D camera (4.4), a cleaning and capping tooling (4.5), a control electric box (4.6), and a conveyor belt I (4.7). The industrial robot I (4.1) is arranged on both sides of the conveyor belt I (4.7). The cleaning and capping tooling (4.5) is installed at the end of the industrial robot I (4.1). The vibrating bowl (4.3) is arranged beside the industrial robot I (4.1). The 3D camera (4.4) is installed on the cleaning and capping tooling (4.5). The control electric box is equipped with a PLC controller for controlling the start, operation, and stop of the industrial robot, vibrating bowl, 3D camera, and conveyor belt I. The cleaning and capping tooling (4.5) includes a cleaning spray gun (4.5.1) and a grasping suction cup (4.5.2). The 3D camera (4.4) is arranged on one side of the grasping suction cup (4.5.2).

3. The automated intelligent unmanned production line for CRTS I type double-block sleepers according to claim 2, characterized in that: The described vibrating bowl (4.3) includes a vibrator (4.3.1) and a rotating disk (4.3.2) arranged on the vibrator (4.3.1). The center of the rotating disk (4.3.2) is a slowly rotating cone. An upward spiral transportation channel (4.3.3) with a capping width is arranged on the inner wall of the rotating disk (4.3.2). The spiral transportation channel (4.3.3) is divided into three layers from the bottom to the top. The top of the second layer of the upper spiral transportation channel (4.3.3) is provided with a first horizontal baffle (4.3.4). The upper top of the first horizontal baffle (4.3.4) is level with the third layer of the channel. The bottom of the first horizontal baffle (4.3.4) is at a distance equal to the thickness of a capping from the plane of the second layer of the channel. A vertical baffle (4.3.5) is arranged on one side of the third layer of the upper spiral transportation channel (4.3.3). A second horizontal baffle (4.3.6) is arranged at the outlet of the third layer. The bottom height of the second horizontal baffle (4.3.6) is at a distance equal to the horizontal height of a capping from the upper plane of the third layer of the channel.

4. The automated intelligent unmanned production line for CRTS I double-block sleepers according to claim 1, characterized in that: On both sides of the bottom of the described grasping tooling (10.4), a left groove (10.4.1) and a right groove (10.4.2) are respectively arranged. A movable groove (10.4.3) is arranged between the left groove (10.4.1) and the right groove (10.4.2). The end of the movable groove (10.4.3) is connected to a cylinder, and the movement of the groove is realized by the telescopic movement of the cylinder. The described welding platform (10.6) is inclined. A pressing plate (10.6.1) and a limit stop (10.6.2) are arranged on the welding platform (10.6). One limit stop (10.6.2) is arranged respectively along the up, down, left, and right directions of the welding platform (10.6). Among them, the limit stops (10.6.2) on the upper, left, and right sides are fixed on the welding platform (10.6), and the limit stop (10.6.2) on the lower side is installed on the cylinder III (10.6.3).

5. The automated intelligent unmanned production line for CRTS I double-block sleepers according to claim 1, characterized in that: The described pressing plate rotating device (10.16) includes a rotating frame (10.21) arranged at the center of the bottom of the fixture (10.10). Both sides of the rotating frame (10.21) are fixedly connected to a hook frame (10.23) through cylinders IV (10.22). A perforation is provided on the hook frame (10.23). The described steel bar assembly platform (10.11) includes a conveyor belt III (10.11.1), a top block (10.11.2), and a hook bending machine (10.11.3). Hook bending machines (10.11.3) are arranged on both sides of the conveyor belt III (10.11.1), a top block (10.11.2) is arranged below the conveyor belt III (10.11.1), and a lifting oil cylinder is arranged at the bottom of the top block (10.11.2).

6. The automated intelligent unmanned production line for CRTS I double-block sleepers according to claim 1, characterized in that: The described concrete precise placing system (12) includes an elevated ash transportation passage (12.1) arranged between the mixing plant and the concrete placing area in the production workshop. An elevated ash transportation trolley (12.2) is provided on the elevated ash transportation passage (12.1); a portal support III (12.3) is arranged in the concrete placing area. Rails II (12.6) are arranged on both upper sides of the portal support III (12.3). A cross beam (12.4) that can move along the rails is arranged on the rails II (12.6). A placing machine (12.5) is installed on the lower side of the cross beam (12.4). A weighing hopper (12.7) is installed at the position of the discharge port below the placing machine (12.5). A roller path (12.9) is arranged below the portal support III (12.3). A double-block sleeper mold (12.8) that can move along the roller path is arranged on the roller path (12.9). A vibrating table (12.11) fixed to the ground is arranged inside the roller path; the described elevated ash transportation trolley (12.2) includes a rectangular bracket (12.12) and a cylindrical roller (12.13). Vertical rods are arranged at the front and rear ends of the rectangular bracket (12.12). Both ends of the cylindrical roller (12.13) are axially connected to the vertical rods. Rollers driven by motors are arranged on both sides of the rectangular bracket (12.12); the upper part of the weighing hopper (12.7) is an inverted trapezoidal cuboid, and the lower part is a regular cuboid. A gate is provided on the lower bottom surface of the weighing hopper (12.7). A gravity sensor (12.14) is connected to one side of the weighing hopper (12.7); the described placing machine (12.5) includes a cube-shaped outer frame (12.15). A cuboid (12.16) with an open top is fixed inside the outer frame (12.15). Two rotatable mixing screw rods are arranged inside the cuboid (12.16). There are 8 outlets at the bottom of the cuboid (12.16), and a gate is provided at each outlet.

7. The automated intelligent unmanned production line for CRTS I double-block sleepers according to claim 1, characterized in that: The described die hoisting and palletizing system (13) includes a gantry support IV (13.2) arranged in the hoisting and palletizing area. On both sides of the top of the gantry support IV (13.2), track III (13.7) is symmetrically arranged. A cross beam (13.3) that can move along it is installed on the track III (13.7). Track IV (13.8) is installed on the top of the cross beam (13.3). A lifting motor II (13.4) that can move along it is installed on the track IV (13.8). At both ends of the cross beam (13.3) and the lifting motor II (13.4), there are rollers and motors. The cross beam (13.3) and the lifting motor II (13.4) are driven by the motors to move the rollers on the track I (13.7) and the track II (13.8) respectively. The lifting motor II (13.4) is connected to a rotating gear (13.5) through a steel wire rope. The top of the rotating gear (13.5) is connected to a motor. A fixture (13.6) is installed at the bottom of the rotating gear (13.5); The fixture (13.6) includes a hollow cross bar (13.6.1). L-shaped steel members ( 13.6.2) are inserted into both ends of the cross bar (13.6.1). The long sides of the L-shaped steel members (13.6.2) are inserted into the cross bar (13.6.1) and connected to the cylinders inside it. The short sides of the L-shaped steel members (13.6.2) are of a bifurcated structure, and hooks are respectively arranged at the ends of the bifurcated structures of the short sides.

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