Automatic and unmanned production system and production method for double-block sleepers

Abstract

The present invention discloses an automated, unmanned production system for double-block sleepers, including a mold detection device, a mold release spraying device, a casing spiral reinforcement installation and re-inspection device, a truss stirrup installation and re-inspection device, a concrete pouring device, a steam curing device, a sleeper detection device, a sleeper buffer curing device, a truss stirrup assembly device, a blow-injection buckle device and a control center, and also includes a mold cleaning device with a double screening function and a sleeper demoulding device with a multi-directional conveying function. The control center is electrically connected to the execution components of each of the above devices, and the above devices form a circular automatic circulation semi-finished product production line and a sleeper finished product production line. All devices in the system can realize automated operation without manual operation of each device, which can save labor costs and improve the efficiency of sleeper production.

Description

Technical Field

[0001] The invention relates to the field of sleeper production equipment, and in particular to an automated and unmanned production system and a production method for a double-block sleeper. Background Art

[0002] With the rapid development of high-speed railways, the demand for sleepers is increasing. In order to meet the requirements, factories have higher and higher requirements for intelligent production of sleeper prefabrication. Traditional production methods can no longer meet the needs of development. First, the most advanced sleeper production line in the industry is not fully automated. For example, some operations in the production process are completely completed manually, and some operations require manual assistance to complete. This makes the sleeper production efficiency low, and there is a lack of key links and quality control methods in construction quality. Second, there are problems with the layout of the traditional sleeper factory, which cannot meet the full automation of all its production processes and cannot achieve the purpose of seamless connection between all production processes. Summary of the invention

[0003] The purpose of the present invention is to overcome the deficiencies of the prior art and to provide an automated, unmanned production system and method for a double-block sleeper.

[0004] The objective of the present invention is achieved through the following technical solutions:

[0005] The automatic and unmanned production system of double-block sleepers includes a mold detection device, a mold release spraying device, a casing spiral reinforcement installation and re-inspection device, a truss stirrup installation and re-inspection device, a truss stirrup assembly device, a concrete pouring device with precise material distribution parts, a steam curing device, a sleeper detection device, a blow-injection buckle device, a control center and a sleeper buffer curing device, and also includes a mold cleaning device with a double screening function and a sleeper demoulding device with a multi-directional conveying function;

[0006] The control center is electrically connected to the execution components of each of the above devices;

[0007] The sleeper demoulding device is provided with a semi-finished product input end for conveying the semi-finished product to the sleeper demoulding device, a finished product output end for conveying the sleeper to the sleeper detection device, and a mold output end for conveying the mold to the mold cleaning device;

[0008] The mold cleaning device, mold detection device, mold release spraying device, casing spiral reinforcement installation and re-inspection device, truss stirrup installation and re-inspection device, concrete pouring device, steam curing device and sleeper demoulding device are sequentially connected to form an automatic circulation semi-finished product production line;

[0009] The mold cleaning device, mold detection device, mold release agent spraying device, casing spiral reinforcement installation and re-inspection device, truss stirrup installation and re-inspection device, concrete pouring device, steam curing device, sleeper demoulding device, sleeper detection device, injection button blowing device and sleeper buffer curing device are sequentially connected to form a finished product production line for producing sleepers;

[0010] The truss stirrup installation and re-inspection device is connected to the output end of the truss stirrup assembly device.

[0011] Further, the mold cleaning device comprises a corundum spray head for mold cleaning, the corundum spray head is arranged on the upper side of the inside of the sand return funnel, a roller for conveying the mold is arranged on the upper side of the sand return funnel, a sandblasting shell connected to the sand return funnel is arranged on the upper side of the roller, a vibrating screen assembly and two sand boxes are arranged on the upper plane of the sandblasting shell, the two sand boxes are respectively located on both sides of the vibrating screen assembly, and the sand boxes are connected to the vibrating screen assembly through a sand feeding auger, the input end of the vibrating screen assembly is connected to a first sand return auger, and the vibrating screen assembly is also provided with a discharge pipe for removing concrete residues, the sand return funnel is provided with a second sand return auger, and the first sand return auger and the second sand return auger are connected through a corundum conveyor belt;

[0012] The return sand funnel is also provided with a diamond sand screen for screening diamond sand, a fixing rod is provided on the upper side of the diamond sand screen, a plurality of diamond sand nozzles are installed on the fixing rod, and the diamond sand nozzles are also provided with a sand inlet, an air inlet and an injection port, the sand inlet is connected to the sand box, and the air inlet is connected to the air compressor outside;

[0013] A dust removal pipeline is also provided on the upper plane of the sandblasting housing, the input end of the dust removal pipeline is connected to the inside of the sandblasting housing, the output end of the dust removal pipeline is provided with a dust removal box, and the dust removal box is provided with a filter rotating motor for extracting dust inside the sandblasting housing;

[0014] The first sand-returning auger, the second sand-returning auger and the sand-returning funnel are all provided with auger rotating motors for providing power for conveying corundum.

[0015] Further, the casing spiral rib installation and re-inspection device comprises a coil spring component for processing spiral ribs, a casing storage component for storing casings, and a casing spiral rib fastening component for tightening the spiral ribs and casings into a casing assembly, the casing spiral rib fastening component is arranged between the coil spring component and the casing storage component, a casing spiral rib conveyor belt is arranged at the lower side of the casing spiral rib fastening component, a casing sorting component for moving the casing from the casing storage component to the upper side of the casing spiral rib conveyor belt is arranged between the casing spiral rib fastening component and the casing storage component, and a spiral rib installation component for moving the spiral rib from the coil spring component to the upper side of the casing spiral rib conveyor belt is arranged between the casing spiral rib fastening component and the coil spring component;

[0016] The sleeve spiral rib installation and re-inspection device also includes a sleeve assembly installation frame, the sleeve assembly installation frame is provided with a sleeve spiral rib installation component for moving the sleeve assembly from the sleeve spiral rib placement table to the mold, the sleeve spiral rib installation component is provided with a first re-inspection component for detecting the sleeve assembly, the lower side of the sleeve spiral rib installation component is provided with a mold conveying roller for conveying the mold, the sleeve spiral rib placement table is arranged between the sleeve assembly installation frame and the sleeve spiral rib fastening component, and the sleeve spiral rib fastening component is provided with a sleeve assembly manipulator for moving the sleeve assembly from the sleeve spiral rib fastening component to the sleeve spiral rib placement table.

[0017] Furthermore, the truss stirrup assembly device includes a truss stirrup assembly component, and also includes a truss feeding component and a stirrup feeding component arranged on both sides of the truss stirrup assembly component;

[0018] The stirrup feeding component includes a stirrup conveying roller for conveying steel stirrups, and also includes a stirrup conveying assembly for transferring the steel stirrups from the steel bar funnel assembly to the stirrup conveying roller, and the output end of the stirrup conveying roller is connected to the truss stirrup assembly component;

[0019] The truss loading component comprises a truss loading outer frame assembly, on which a first truss clamping claw for clamping, flipping and moving the steel bar truss is symmetrically arranged, a truss receiving platform for supporting the steel bar truss is arranged at the lower side of the first truss clamping claw, a truss conveying platform for conveying the truss receiving platform is arranged at the lower side of the truss receiving platform, a movable truss storage platform is arranged at the input side of the truss conveying platform, and an inverted triangle is arranged at the upper end of the truss receiving platform for preventing the steel bar truss from deflecting and cooperating with the truss stirrups;

[0020] The truss stirrup assembly component comprises a stirrup conveyor belt connected to the output end of the stirrup conveyor roller and used for conveying the steel stirrups, the output end of the stirrup conveyor belt is provided with a truss stirrup assembly outer frame, the truss stirrup assembly outer frame is provided with a second truss clamping claw member for clamping the steel bar truss, the truss stirrup assembly outer frame is connected to the output end of the truss conveyor belt, the truss conveyor belt and the stirrup conveyor belt are arranged oppositely, one side of the input end of the truss conveyor belt contacts with the output end of the truss conveying platform, and the upper side of the truss conveyor belt is provided with a third truss clamping claw member for conveying the steel bar truss from the truss receiving platform to the truss conveyor belt;

[0021] The truss stirrup assembly component also includes a hook clamping member for clamping the hook, and a hook conveyor belt for transporting the hook clamping member, the output end of the hook conveyor belt is located at the lower side of the second truss clamping claw member, and the input end of the hook conveyor belt is provided with a hook storage assembly for storing the hook;

[0022] The truss stirrup assembly component also includes a truss stirrup installation component for installing the hook on the steel bar truss, and the truss stirrup installation component also installs the steel stirrup on the hook. After the hook and the steel stirrup are installed on the steel bar truss, the truss stirrup is formed;

[0023] The output end of the truss stirrup assembly device is the second truss clamping claw member, which clamps the truss stirrups and moves on the truss stirrup assembly outer frame, and puts the truss stirrups into the truss stirrup installation and re-inspection device.

[0024] Further, the rail sleeper demoulding device comprises a truss outer frame component, the truss outer frame component comprises a truss crossbeam assembly, a storage component for temporarily storing semi-finished products is arranged on the lower side of the truss crossbeam assembly, a demoulding component for separating the mold and the rail sleeper is also arranged on the lower side of the truss crossbeam assembly, a mold clamping component for conveying and turning over the semi-finished products is connected to the truss crossbeam assembly, the mold clamping component is located on the upper side of the storage component and can convey the semi-finished products to the demoulding component;

[0025] Further, the concrete pouring device includes a feeding component for conveying concrete from the stirring component to the precise material distribution component, the precise material distribution component includes a material distribution machine hopper with a quantitative loading function, a plurality of weighing container components are provided on the lower side of the material distribution machine hopper, a plurality of closable first material discharge ports are provided at the bottom of the material distribution machine hopper, each of the first material discharge ports is correspondingly arranged directly above the weighing container component, a closable second material discharge port is provided on the lower side of the weighing container component, a material discharge port driving component for opening / closing the second material discharge port is provided on the second material discharge port, the outlets of the second material discharge ports are all provided on the upper side of the mold cavity, the precise material distribution component is provided with a stirring component for preventing concrete from coagulation, and the precise material distribution component and the feeding component are both provided on a bracket with a guide rail;

[0026] Two groups of the heavy container assemblies are arranged at the lower side of the material placing machine hopper, each group is provided with four heavy container assemblies, and the volumes of all the heavy container assemblies are equal;

[0027] The concrete pouring device also includes a vibrating component for compacting the concrete.

[0028] Further, the demoulding assembly includes symmetrically arranged action pieces, the action pieces include a lifting platform, a demoulding platform and a detection platform, the detection platforms on both sides are arranged between the demoulding platforms on both sides, and the demoulding platforms on both sides are arranged between the lifting platforms on both sides;

[0029] The lifting platform is provided with a first lifting member for lifting the mold, the demoulding platform is provided with a second lifting member for lifting the semi-finished product, and the detection platforms on both sides are provided with a plurality of detection members for detecting whether the mold and the sleeper are separated;

[0030] A mold pillow conveying track is arranged between the detection tables on both sides, a sleeper conveying assembly and a mold conveying assembly are arranged on the mold pillow conveying track, and a third lifting member is arranged on both the sleeper conveying assembly and the mold conveying assembly;

[0031] The end of the sleeper demoulding device where the storage component is located is the semi-finished product input end and is connected to the steam curing device, the end where the sleeper transport component is located is the finished product output end and is connected to the sleeper detection device, and the end where the mold transport component is located is the mold output end and is connected to the mold cleaning device;

[0032] The first lifting member, the second lifting member and the third lifting member are all lifting cylinders.

[0033] Furthermore, the blow-injection buckle device comprises a sleeper transmission track for conveying double-block sleepers, and both sides of the sleeper transmission track are provided with a manipulator component with a motion function, and the upper end of the manipulator component is provided with an integrated and rotatable base;

[0034] The base is provided with a 3D camera capable of monitoring and positioning, an air blowing port connected to an air supply component, an oil filling port connected to an oil supply component, and a cover assembly for covering the sleeve hole;

[0035] The upper surface of the base is connected to the manipulator component, the buckle cover assembly is arranged on the lower surface of the base, and the 3D camera, the air blowing port and the oil filling port are all arranged on the side of the base;

[0036] The buckle cover assembly comprises a pick-up piece matched with the inner hole of the end of the buckle cover, a through hole is arranged inside the pick-up piece, and a pressing piece which can move along the through hole and is used to press the buckle cover into the sleeve hole on the sleeper is arranged in the through hole;

[0037] The input end of the pressing member is connected to the piston on the cylinder, and the cylinder body of the cylinder is arranged inside the base.

[0038] Further, the control center includes a start button for starting the production system and a stop button for shutting down the production line;

[0039] The mold is provided with a sleeve assembly installation position, a truss stirrup installation position and a mold number;

[0040] The mold detection device includes a first laser image detection component with an image detection function, a mold identification component for identifying the mold number, and a mold selection component for picking out damaged molds;

[0041] The release agent spraying device comprises a release agent spraying component filled with a release agent and a flipping component for flipping the mold so that its inner cavity faces upward;

[0042] The truss stirrup installation and re-inspection device includes a second re-inspection component for detecting the truss stirrup and the truss stirrup installation position;

[0043] The sleeper detection device comprises a second laser image detection component with an image detection function, a sleeper identification component for detecting the sleeper, and a coding component for coding.

[0044] Furthermore, the production method of the production system is characterized by comprising the following steps:

[0045] S1: Press the start button to start the semi-finished product production line with automatic circulation function and the finished product production line for producing sleepers at the same time;

[0046] S2: Cleaning the concrete residue in the inner cavity of the mold in the mold cleaning device with dual screening function;

[0047] S3: In the mold detection device, the first laser image detection component detects whether the mold inner cavity is damaged. If the mold inner cavity is not damaged, the mold enters the sleeve spiral rib installation and re-inspection device; if the mold inner cavity is damaged, the mold selection component pushes the mold out of the production line, and the mold identification component identifies the mold number and generates a first inspection report;

[0048] S4: In the release agent spraying device, the release agent spraying component sprays the release agent on the inner cavity of the mold, and at the same time, the flipping component flips the mold so that the inner cavity of the mold faces upward;

[0049] S5: In the sleeve spiral rib installation and re-inspection device, the sleeve and the spiral rib are combined into a sleeve assembly, and the sleeve assembly is installed on the sleeve assembly installation position in the mold cavity, and the first re-inspection component monitors the installation position of the sleeve assembly;

[0050] S6: In the truss stirrup installation and re-inspection device, the second truss clamping claw member clamps the truss stirrup and installs the truss stirrup in the truss stirrup installation position on the mold, and the second re-inspection component monitors whether the truss stirrup is correctly installed in the truss stirrup installation position on the mold. If it is monitored that the truss stirrup is correctly installed in the truss stirrup installation position, the mold enters the concrete pouring device; if it is monitored that the truss stirrup is not correctly installed in the truss stirrup installation position, the second re-inspection component transmits the position information of the truss stirrup and the truss stirrup installation position to the control center, and the control center transmits the information to the second truss clamping claw member, and the second truss clamping claw member corrects the position of the truss stirrup. After the correction is completed, the mold enters the concrete pouring device;

[0051] Wherein, before installing the truss stirrups, the truss stirrups are assembled in the truss stirrup assembly device;

[0052] S7: In the concrete pouring device, the pouring component pours concrete into the inner cavity of the mold, and the vibrating component compacts the poured concrete;

[0053] S8: steam-curing the semi-finished product in the steam curing device;

[0054] S9: performing a separation operation between the mold and the sleeper in the sleeper demoulding device;

[0055] S10: In the sleeper detection device, the second laser image detection component detects the outer dimensions of the sleeper, the sleeper identification component detects the appearance quality of the sleeper, and outputs the detected outer dimension information and the detected appearance quality information to the control center, the control center generates a second detection report based on the information, and forms a serial code and a two-dimensional code based on the second detection report, and then transmits the serial code and the two-dimensional code information to the coding component, and the coding component prints the serial code and the two-dimensional code on the label of the sleeper;

[0056] S11: In the blowing and injection buckle device, the 3D camera first identifies the position information of the casing hole on the sleeper and transmits the position information to the control center, and the control center then transmits the information to the manipulator component, and the manipulator component adjusts the air blowing port to a position relative to the casing hole, and the air blowing component blows air to the casing hole through the air blowing port and removes concrete residue. When the concrete residue in the casing hole is removed; the manipulator component adjusts the oil filling port to a position relative to the casing hole, and the oil filling component injects oil into the casing hole through the oil filling port. When the oil filling of the casing hole is completed; the buckle cover component on the manipulator component grabs the buckle cover and inserts it into the casing hole;

[0057] S12: performing constant temperature and constant humidity maintenance on the sleeper in the sleeper buffer maintenance device;

[0058] S13: Press the stop button to end the operation of the semi-finished product production line and the finished product production line.

[0059] Furthermore, the production method of S2 comprises the following sub-steps:

[0060] S2.1: transporting the mold to the upper side of the sand return funnel through a roller conveyor;

[0061] S2.2: The air compressor ejects high-speed airflow through the air inlet;

[0062] S2.3: The corundum in the sandbox is mixed with the high-speed airflow in the corundum nozzle through the sand inlet;

[0063] S2.4: The high-speed airflow is mixed with corundum and sprayed into the mold cavity through the injection port to clean the concrete residue;

[0064] S2.5.: The carborundum and concrete residue are mixed and then fall onto the carborundum screen for the first filtration;

[0065] S2.6: The filtered corundum and concrete residues enter the sand box through the second sand return auger, the corundum conveyor belt and the first sand return auger;

[0066] S2.7: Perform a second filtration in the sandbox, the filtered corundum is stored in the sandbox and can be used in the next cycle, and the concrete residue is discharged through the discharge pipe;

[0067] S2.8: After the set time, the cleaning work is completed;

[0068] The production method of S5 comprises the following sub-steps:

[0069] S5.1: the casing sorting component moves the casing from the casing storage component to the upper side of the casing spiral rib conveyor belt;

[0070] S5.2: The spiral rib installation component moves the spiral rib from the coil spring component to the sleeve for preliminary assembly;

[0071] S5.3: The casing and spiral rib conveyor belt conveys the casing and spiral rib to the casing and spiral rib fastening component for screwing and assembly;

[0072] S5.4: The casing assembly manipulator moves the assembled casing assembly from the casing spiral rib fastening component to the casing spiral rib placement table;

[0073] S5.5: The casing spiral rib installation component moves the casing assembly from the casing spiral rib placement table to the casing assembly installation position in the mold and assembles it;

[0074] S5.6: The first re-inspection component monitors whether the sleeve assembly is correctly installed on the sleeve assembly installation position in the inner cavity of the mold. If it is monitored that the sleeve assembly is correctly installed on the sleeve assembly installation position, the mold enters the truss stirrup installation and re-inspection device; if it is monitored that the sleeve assembly is not correctly installed on the sleeve assembly installation position, the first re-inspection component transmits the position information of the sleeve assembly and the sleeve assembly installation position to the control center, and the control center transmits the information to the sleeve spiral reinforcement installation component, and the sleeve spiral reinforcement installation component corrects the position of the sleeve assembly. After the correction is completed, the mold enters the truss stirrup installation and re-inspection device;

[0075] The truss stirrup assembly method in S6 comprises the following sub-steps:

[0076] S6.1: The first truss clamp moves the steel truss from the truss storage platform to the truss receiving platform, and flips the steel truss during the movement;

[0077] S6.2: The truss conveying platform moves the truss receiving platform equipped with the steel bar truss to one side of the input end of the truss conveyor belt;

[0078] S6.3: The third truss clamping claw member clamps the steel bar truss and places it on the truss conveyor belt, and the truss conveyor belt conveys the steel bar truss to the truss stirrup assembly component;

[0079] S6.4: The second truss clamping claw member on the truss stirrup assembly component clamps the steel bar truss conveyed by the truss conveyor belt;

[0080] S6.5: The hook clamping member takes the hook out of the storage assembly and conveys the hook to the truss stirrup assembly component via the hook conveyor belt, and the truss stirrup installation assembly installs the hook on the steel bar truss;

[0081] S6.6: The stirrup conveying assembly takes the steel stirrups out of the steel bar funnel assembly and places them on the stirrup conveying roller, the steel stirrups on the stirrup conveying roller are conveyed to the truss stirrup assembly component through the stirrup conveyor belt, and the truss stirrup installation assembly installs the steel stirrups on the hooks on the steel bar truss;

[0082] S6.7.: The second truss clamping claw member on the truss stirrup assembly component transports the truss stirrups assembled from the steel truss, the hook and the steel stirrups to the truss stirrup installation and re-inspection device;

[0083] The production method of S9 comprises the following sub-steps:

[0084] S9.1: conveying the semi-finished product to the storage assembly;

[0085] S9.2: The mold clamping component clamps the semi-finished product from the storage component and conveys it to the demoulding component. During the conveying process, the mold clamping component turns the semi-finished product over;

[0086] S9.3: After placing the semi-finished product on the demoulding component, the mold clamping component returns to the upper side of the storage component and stops conveying the next semi-finished product;

[0087] S9.4: the second lifting member on the demoulding assembly continuously and rapidly lifts up and lowers the semi-finished product, and the first lifting member prevents the mold from falling but does not prevent the sleeper from falling;

[0088] S9.5: The detection member on the detection table detects whether the sleeper is separated from the mold. If it is detected that the sleeper is not separated from the mold, the second lifting member continues to work and the mold clamping member does not transport the semi-finished product. If it is detected that all the sleepers are separated from the mold, the first lifting member pushes the mold upwards and has a certain distance from the upper side of the sleeper;

[0089] S9.6: The sleeper transport assembly enters the lower side of the sleeper through the sleeper mold conveying track, and the third jacking member on the sleeper transport assembly pushes the sleeper upward. When the sleeper is separated from the demoulding assembly, the sleeper transport assembly transports the sleeper to the sleeper detection device;

[0090] S9.7: After the rail sleeper is transported, the first lifting member descends, and the mold on the upper side thereof moves downward, and at the same time, the mold transport assembly enters the lower side of the mold, and the third lifting member on the mold transport assembly pushes the mold upward, and when the mold is separated from the demoulding assembly, the mold transport assembly transports the rail sleeper to the mold cleaning device;

[0091] S9.8: After the mold is transported, the mold clamping component starts to transport the semi-finished product again.

[0092] The beneficial effects of the present invention are:

[0093] 1) All devices in this system can realize automatic operation, and there is no need to manually operate each device, which can save labor costs. As the degree of automation of the production line is improved, the efficiency of sleeper production is also improved.

[0094] 2) After the mold is demoulded, the system enters the mold cleaning station to form a circular mold self-circulation line, so that the mold can be fully utilized. At the same time, the production line is seamlessly connected, making the production line more automated.

[0095] 3) In the mold cleaning device, manual mold cleaning is improved to automatic mold cleaning, and the corundum used for mold cleaning is recycled, which can effectively save costs. The dust removal box is equipped with a filter rotating motor, which can effectively absorb the dust generated during the mold cleaning process, so that the production line will not be polluted by the dust generated during the mold cleaning process.

[0096] 4) In the concrete pouring device, the process of adding the concrete in the feeding component to the hopper of the concrete placing machine can be used for the first material control, and the concrete in the hopper of the concrete placing machine enters the weighing container assembly for the second precise material control. Since the volume of the weighing container assemblies is the same, and the volume of each weighing container assembly is the same as the volume of concrete required for each inner cavity in the mold, putting all the concrete in each weighing container assembly into it at one time can meet the production needs and achieve the purpose of completely precise material control.

[0097] 5) The blowing and injection buckle device can blow air into the casing hole of the sleeper to remove impurities in the casing hole. After the impurities are removed, oil is injected into the casing hole. After the oil injection is completed, the buckle cover is covered on the outside of the casing hole. In the traditional production process, three devices are required to complete such a task, while the automated production line can complete its operation in one device, which can reduce the length of the production line and save space. In addition, the sleepers do not need to be moved during the three processes, which can save time costs and reduce energy consumption. BRIEF DESCRIPTION OF THE DRAWINGS

[0098] Figure 1 The schematic diagram of the sleeper structure from a bird's-eye view is shown in Figure 1.

[0099] Figure 2 It is a schematic diagram of the mold structure from a top view;

[0100] Figure 3 It is a schematic diagram of the connection structure of the production line;

[0101] Figure 4 It is a structural schematic diagram of a mold cleaning device;

[0102] Figure 5 It is a schematic diagram of the partial structure inside the mold cleaning device;

[0103] Figure 6 This is a schematic diagram of the structure of the diamond abrasive nozzle;

[0104] Figure 7 It is a schematic diagram of the connection structure of the casing spiral reinforcement installation and re-inspection device;

[0105] Figure 8 It is a schematic diagram of the connection structure of the stirrup feeding parts;

[0106] Fig. 9 It is a schematic diagram of the connection structure of the truss feeding parts;

[0107] Fig.10 It is a schematic diagram of the connection structure of the truss stirrup assembly components;

[0108] Fig.11 for Fig.10 A magnified schematic diagram of point A;

[0109] Fig.12 It is a schematic diagram of the connection structure of the concrete pouring device;

[0110] Fig.13 It is a schematic diagram of the main structure of the precision fabric component;

[0111] Fig.14 It is a top view structural diagram of the precision fabric component;

[0112] Fig.15It is a schematic diagram of the connection structure of the demoulding device;

[0113] Fig.16 It is a schematic diagram of the connection structure of the blow-injection button device;

[0114] Fig.17 It is a schematic diagram of the connection structure at the end of the robot component;

[0115] Fig.18 It is a front view schematic diagram of the connection structure of the end of the robot component;

[0116] In the figure, 1-mold cleaning device, 2-mold detection device, 3-mold release agent spraying device, 4-sleeper spiral reinforcement installation and re-inspection device, 5-precision material distribution parts, 6-truss stirrup installation and re-inspection device, 7-truss stirrup assembly device, 8-concrete pouring device, 9-steam curing device, 10-sleeper demoulding device, 11-sleeper detection device, 12-sleeper, 13-blow injection buckle device, 14-mold, 15-control center, 16-sleeper buffer maintenance device, 17-discharge pipe, 18-emery nozzle, 19-return sand funnel, 20-roller, 21-sandblasting shell, 22-vibrating screen assembly, 23-sand box, 24-sand feeding auger, 25-first return sand auger, 26-second return sand auger, 2 7-emery conveyor belt, 28-emery screen, 29-fixing rod, 30-sand inlet, 31-dust removal pipeline, 32-dust removal box, 33-filter rotating motor, 34-auger rotating motor, 35-sleeper transmission track, 36-manipulator component, 37-base, 38-3D camera, 39-air blowing port, 40-oil filling port, 41-buckle cover assembly, 42-air inlet, 43-injection port, 44-truss beam assembly, 45-storage assembly, 46-demolding assembly, 47-mold clamping component, 48-lifting platform, 49-demolding platform, 50-testing platform, 51-first lifting part, 52-second lifting part , 53-detection parts, 54-mold pillow conveying track, 55-sleeper transport assembly, 56-mold transport assembly, 57-third jacking parts, 58-stirrup conveying roller, 59-stirrup conveying assembly, 60-steel funnel assembly, 61-truss feeding outer frame assembly, 62-first truss clamping parts, 63-truss receiving platform, 64-truss conveying platform, 65-truss storage platform, 66-stirrup conveyor belt, 67-truss stirrup assembly outer frame, 68-second truss clamping parts, 69-truss conveyor belt, 70-third truss clamping parts, 71-hook clamping parts, 72-hook conveyor belt, 73-truss stirrup installation assembly , 74-truss stirrups, 75-casing holes, 76-label, 77-casing assembly installation position, 78-truss stirrup installation position, 79-coil spring component, 80-casing storage component, 81-casing spiral reinforcement fastening component, 82-casing spiral reinforcement conveyor belt, 83-casing sorting component, 84-spiral reinforcement installation component, 85-casing assembly mounting frame, 86-casing spiral reinforcement placement table, 87-casing spiral reinforcement installation component, 88-first re-inspection component, 89-mold conveying roller, 90-casing assembly manipulator, 91-feeding component, 92-fabricating machine hopper, 93-weighing container component, 94-first discharge port, 95-second discharge port, 96-discharge port drive component, 97-stirring component. DETAILED DESCRIPTION

[0117] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0118] See also Figure 3-17 , the present invention provides a technical solution:

[0119] like Figure 1 The sleeper 12 shown has a structure of two truss stirrups arranged in parallel, and the truss stirrups are all cast with concrete castings. Two sleeve holes 75 and two labels 76 are provided on each concrete casting. The sleeve holes 75 are used to install fixings for fixing the rails, and the labels 76 are used to engrave other information such as production time and address.

[0120] like Figure 2 The mold 14 shown can produce four sleepers 12 at the same time. The mold 14 is provided with a sleeve assembly installation position 77, a truss stirrup installation position 78 and a mold number.

[0121] The automatic and unmanned production system of double-block sleepers comprises a mold detection device 2, a mold release agent spraying device 3, a casing spiral reinforcement installation and re-inspection device 4, a truss stirrup installation and re-inspection device 6, a truss stirrup assembly device 7, a concrete pouring device 8 with a precise material distribution component 5, a steam maintenance device 9, a sleeper detection device 11, a blow-injection buckle device 13, a control center 15 and a sleeper buffer maintenance device 16, and is characterized in that it also includes a mold cleaning device 1 with a double screening function and a sleeper demoulding device 10 with a multi-directional conveying function; the control center 15 is electrically connected to the actuators of the above-mentioned devices; the sleeper demoulding device 10 is provided with a semi-finished product input end for conveying the semi-finished product to the sleeper demoulding device 10, a finished product output end for conveying the sleeper 12 to the sleeper detection device 11 and a mold output end for conveying the mold 14 to the mold cleaning device 1.

[0122] The mold cleaning device 1, the mold detection device 2, the mold release agent spraying device 3, the casing spiral reinforcement installation and re-inspection device 4, the truss stirrup installation and re-inspection device 6, the concrete pouring device 8, the steam curing device 9 and the sleeper demoulding device 10 are sequentially connected to form an automatic circulation semi-finished product production line.

[0123] The mold cleaning device 1, the mold detection device 2, the mold release agent spraying device 3, the casing spiral reinforcement installation and re-inspection device 4, the truss stirrup installation and re-inspection device 6, the concrete pouring device 8, the steam curing device 9, the sleeper demoulding device 10, the sleeper detection device 11, the blow-injection buckle device 13 and the sleeper buffer curing device 16 are connected in sequence to form a finished product production line for producing sleepers 12; the truss stirrup installation and re-inspection device 6 is connected to the output end of the truss stirrup assembly device 7.

[0124] The mold cleaning device 1 includes a corundum nozzle 18 for mold cleaning, which is arranged on the upper side of the inside of a sand return funnel 19. A roller 20 for conveying the mold is arranged on the upper side of the sand return funnel 19. A sandblasting shell 21 connected to the sand return funnel 19 is arranged on the upper side of the roller 20. A vibrating screen assembly 22 and two sand boxes 23 are arranged on the upper plane of the sandblasting shell 21. The two sand boxes 23 are respectively located on both sides of the vibrating screen assembly 22, and the sand boxes 23 are connected to the vibrating screen assembly 22 through a sand feeding auger 24. The input end of the vibrating screen assembly 22 is connected to a first sand return auger 25. The vibrating screen assembly 22 is also provided with a discharge pipe 17 for removing concrete residues. A second sand return auger 26 is arranged on the sand return funnel 19, and the first sand return auger 25 and the second sand return auger 26 are connected through a corundum conveyor belt 27.

[0125] A corundum screen 28 for screening corundum is also provided in the return sand funnel 19, a fixing rod 29 is provided on the upper side of the corundum screen 28, and a plurality of corundum nozzles 18 are installed on the fixing rod 29. The corundum nozzles 18 are also provided with a sand inlet 30, an air inlet 42 and an injection port 43. The sand inlet 30 is connected to the sand box 23, and the air inlet 42 is connected to the air compressor outside.

[0126] Preferably, a dust removal pipeline 31 is also provided on the upper plane of the sandblasting housing 21, the input end of the dust removal pipeline 31 is connected to the inside of the sandblasting housing 21, and a dust removal box 32 is provided at the output end of the dust removal pipeline 31, and a filter rotating motor 33 for extracting dust from the inside of the sandblasting housing 21 is provided on the dust removal box 32. The first sand return auger 25, the second sand return auger 26 and the sand return funnel 19 are all provided with an auger rotating motor 34 for providing power for conveying corundum. A filter rotating motor 33 is provided in the dust removal box 32, and the high-speed rotation of the filter rotating motor 33 can effectively absorb the dust generated during the mold cleaning process, so that the production line will not be polluted by the dust generated during the mold cleaning process, and the environmental quality of the production workshop is guaranteed.

[0127] Door curtains for preventing dust from leaking out are arranged at the entrance and exit of the roller conveyor 20. The door curtains, the sandblasting housing 21 and the sand return funnel 19 together form a closed mold cleaning space. The injection port 43 is arranged on the upper end surface of the diamond sand spray head 18 and is arranged vertically upward. The air inlet 42 is arranged on the lower end surface of the diamond sand spray head 18. The sand inlet 30 is arranged on the side of the diamond sand spray head 18 and is close to the injection port 43. The diamond sand screen 28 is provided with screening holes for filtering diamond sand.

[0128] The process of the mold cleaning device 1 is as follows: the corundum entering from the sand inlet 30 and the high-speed airflow entering from the air inlet 42 are mixed in the corundum nozzle 18, and then ejected from the ejection port 43 on the corundum nozzle 18. The high-speed corundum hits the mold, causing the concrete residue remaining in the mold to fall after being hit by the corundum, thereby achieving the purpose of cleaning the mold. The corundum in the mold cleaning device 1 is screened for the first time through the corundum screen 28. After the first screening, the large particles of concrete residue remain on the corundum screen 28, and the small particles of concrete residue and the corundum enter the vibrating screen assembly 22 through the second sand return auger 26, the corundum conveyor belt 27 and the first sand return auger 25, and the second screening is performed in the vibrating screen assembly 22. After the second screening, the corundum is separated from the small-particle concrete slag, wherein the corundum enters the sand box 23 through the sand feeding auger 24, while the small-particle concrete slag is discharged through the discharge pipe 17. The corundum in the sand box 23 is directly transmitted to the sand inlet 30 on the corundum nozzle 18, so that the corundum can be recycled and the cost can be effectively saved. At the same time, a recycling box is provided at the output end of the discharge pipe 17, and the small-particle concrete slag is discharged into the recycling box. The large-particle concrete slag on the corundum screen 28 is manually cleaned and discharged. The mold is inverted and automatically transmitted to the mold cleaning station through the track, and the inner cavity of the mold is fully polished by the sandblasting process. After the sandblasting is completed, the residue on the surface of the mold is thoroughly cleaned by an air knife, so that the automatic mold cleaning can be satisfied.

[0129] In the mold detection device 2, a first laser image detection component with an image detection function, a mold identification component for identifying the mold number, and a mold selection component for picking out damaged molds are used. In this way, the laser image detection technology and the rail sleeper automatic detection system can be used to automatically identify the mold number, detect and determine the limit deviation of the mold, the damage of the label, etc., and generate a detection report, so that the mold with problems can be picked out for repair in time.

[0130] The release agent spraying device 3 includes a release agent spraying component filled with a release agent and a flipping component for flipping the mold 14 to its inner cavity facing upward. The release agent spraying device 3 is a system, and the above-mentioned components are only some of the executive components in this system. This system adopts a fully automatic control system for spraying to realize automatic positioning of the mold and uniform spraying of the release agent. When the sensor senses that the mold has reached the specified position, the nozzle is aimed at the inner cavity of the mold, and the atomized release agent is evenly sprayed into the mold cavity. At the same time, the mist absorption device will recover the scattered atomized release agent to avoid environmental pollution. The release agent recovery device will wrap the entire mold to ensure that the release agent does not leak out and ensure the environmental hygiene in the site. A new automatic cleaning nozzle system is added to prevent nozzle clogging. At the same time, the recovery is automatically controlled according to the beat, which is more energy-saving. After the spraying is completed, the mold is flipped 180° so that the inner cavity faces upward to enter the next process.

[0131] The casing spiral rib installation and re-inspection device 4 includes a coil spring component 79 for processing spiral ribs, a casing storage component 80 for storing casings, and a casing spiral rib fastening component 81 for tightening the spiral ribs and casings into a casing assembly. The casing spiral rib fastening component 81 is arranged between the coil spring component 79 and the casing storage component 80. A casing spiral rib conveyor belt 82 is arranged on the lower side of the casing spiral rib fastening component 81. A casing sorting component 83 for moving the casing from the casing storage component 80 to the upper side of the casing spiral rib conveyor belt 82 is arranged between the casing spiral rib fastening component 81 and the casing storage component 80. A spiral rib installation component 84 for moving the spiral rib from the coil spring component 79 to the upper side of the casing spiral rib conveyor belt 82 is arranged between the casing spiral rib fastening component 81 and the coil spring component 79.

[0132] The sleeve spiral rib installation and re-inspection device 4 also includes a sleeve assembly installation frame 85, on which is provided a sleeve spiral rib installation component 87 for moving the sleeve assembly from the sleeve spiral rib placement table 86 to the mold 14, on which is provided a first re-inspection component 88 for detecting the sleeve assembly, on which is provided a mold conveying roller 89 for conveying the mold 14, on the lower side of the sleeve spiral rib installation component 87, the sleeve spiral rib placement table 86 is arranged between the sleeve assembly installation frame 85 and the sleeve spiral rib fastening component 81, and on which is provided a sleeve assembly robot 90 for moving the sleeve assembly from the sleeve spiral rib fastening component 81 to the sleeve spiral rib placement table 86.

[0133] The casing spiral rib installation and re-inspection device 4 includes two systems, and the above-mentioned parts are only some of the executive components in these two systems. One is a fully automatic casing, spiral rib assembly and installation platform equipment system, which includes a spring winding mechanism, a spiral rib installation robot, a casing storage device, a casing conveying and sorting system, a casing spiral rib conveyor belt system, a casing spiral rib fastening clamp, a casing spiral rib stacking robot, a casing spiral rib installation system, a casing spiral rib placement platform, etc. The casing sorting system automatically sorts the casing according to the specified direction and position, and the spiral rib installation robot grabs the spiral rib produced by the spring winding mechanism of the spiral rib equipment, and automatically rotates and assembles it on the casing. The casing after the spiral rib is installed is transported to the casing spiral rib fastening clamp through the casing spiral rib conveyor belt system, and the spiral rib is further tightened for installation quality. The casing spiral rib stacking robot then stacks the casing spiral rib assembly on the casing spiral rib placement platform. The casing spiral rib installation system uses vision and intelligent casing infrared re-inspection systems to identify the position of the casing assembly and the installation position in the mold cavity, and accurately install the casing assembly in the mold. The other is the intelligent casing re-inspection device system. The position sensor and servo motor torque sensing system of this system will detect whether the casing assembly is installed in place. If it is installed in place, it will enter the next process. If it is not installed in place, it will continue to correct it in this process. After the correction is completed, it will enter the next process. At the same time, a new linear walking and visual inspection system is added to re-inspect and monitor the casing installation quality.

[0134] The truss stirrup assembly device 7 includes a truss stirrup assembly component, and also includes a truss loading component and a stirrup loading component arranged on both sides of the truss stirrup assembly component. The stirrup loading component includes a stirrup conveying roller 58 for conveying steel stirrups, and also includes a stirrup conveying component 59 for transferring steel stirrups from a steel bar funnel component 60 to the stirrup conveying roller 58, and the output end of the stirrup conveying roller 58 is connected to the truss stirrup assembly component. The truss loading component includes a truss loading outer frame component 61, and the truss loading outer frame component 61 is symmetrically provided with a first truss clamping claw 62 for clamping, flipping and moving the steel bar truss, and the lower side of the first truss clamping claw 62 is provided with a truss receiving platform 63 for supporting the steel bar truss, and the lower side of the truss receiving platform 63 is provided with a truss conveying platform 64 for conveying the truss receiving platform 63, and the input side of the truss conveying platform 64 is provided with a movable truss storage platform 65. The upper end of the truss receiving platform 63 is provided with an inverted triangle truss stirrup assembly component for preventing the steel truss from deflecting and cooperating with the truss stirrups 74, including a stirrup conveyor belt 66 connected to the output end of the stirrup conveying roller 58 and used to convey the steel stirrups, the output end of the stirrup conveyor belt 66 is provided with a truss stirrup assembly outer frame 67, the truss stirrup assembly outer frame 67 is provided with a second truss clamping member 68 for clamping the steel truss, the truss stirrup assembly outer frame 67 is connected to the output end of the truss conveyor belt 69, the truss conveyor belt 69 is arranged opposite to the stirrup conveyor belt 66, one side of the input end of the truss conveyor belt 69 is in contact with the output end of the truss conveying platform 64, and the upper side of the truss conveyor belt 69 is provided with a third truss clamping member 70 for conveying the steel truss from the truss receiving platform 63 to the truss conveyor belt 69. The welded steel stirrups are stored in the steel bar funnel assembly 60 through the stirrup conveying assembly 59. The steel stirrups are fed by the feeding motor. The stirrup conveying assembly 59 clamps and conveys the steel stirrups to the stirrup conveying roller 58 through the electromagnetic adsorption principle. The stirrups are then conveyed to the truss stirrup assembly part through the stirrup conveying roller 58. The welded steel bar trusses are placed on the truss storage platform 65, and are clamped, turned over and moved by the first truss clamping claw 62 of the truss feeding part, and conveyed to the truss receiving platform 63. The steel bar trusses are conveyed to the truss stirrup assembly part through the truss conveying platform 64.

[0135] The truss stirrup assembly component also includes a hook clamp 71 for clamping the hook, and a hook conveyor belt 72 for transporting the hook clamp 71. The output end of the hook conveyor belt 72 is located at the lower side of the second truss clamping claw 68. The input end of the hook conveyor belt 72 is provided with a hook storage assembly for storing the hook. The truss stirrup assembly component also includes a truss stirrup installation assembly 73 for installing the hook on the steel truss. The truss stirrup installation assembly 73 also installs the steel stirrup on the hook. After the hook and the steel stirrup are installed on the steel truss, the truss stirrup 74 is formed.

[0136] The output end of the truss stirrup assembly device 7 is the second truss clamping claw member 68. The second truss clamping claw member 68 clamps the truss stirrup 74 and moves on the truss stirrup assembly outer frame 67, and puts the truss stirrup 74 into the truss stirrup installation and re-inspection device 6.

[0137] The truss stirrup installation and re-inspection device 6 includes a second re-inspection component for detecting the truss stirrups 74 and the truss stirrup installation position.

[0138] The truss stirrup installation and re-inspection device 6 is a system, and the above-mentioned components are only some of the executive components in this system. The full name of the system is the intelligent truss steel bar, stirrup automatic installation, and re-inspection equipment system. The internal truss grabbing and transfer system, hook installation system, truss clamping system, stirrup clamping and lifting system, overall transverse movement system, conveyor roller, and re-inspection system. The truss stirrup assembly device automatically assembles the steel bar truss and the welded steel stirrups and hooks together, and transports the assembled truss stirrup components to the mold, accurately controls the assembly action, and re-inspects the assembled truss by identifying the precise positioning and placement position, identifies the buckling device, and automatically lifts the buckling plate to press the truss.

[0139] The concrete pouring device 8 includes a feeding component 91 for conveying concrete from the stirring component to the precise distribution component 5. The precise distribution component 5 includes a distribution machine hopper 92 with a quantitative loading function. The lower side of the distribution machine hopper 92 is provided with a plurality of weighing container components 93. The bottom of the distribution machine hopper 92 is provided with a plurality of closable first discharge ports 94. Each first discharge port 94 is correspondingly arranged directly above the weighing container component 93. The lower side of the weighing container component 93 is provided with a closable second discharge port 95. The second discharge port 95 is provided with a useful A feeding port driving assembly 96 is provided for opening / closing the second feeding port 95, and the outlet of the second feeding port 95 is arranged on the upper side of the mold cavity. The precise material distribution component 5 is provided with a stirring assembly 97 to prevent the concrete from coagulating. The precise material distribution component 5 and the feeding component 91 are both arranged on a bracket with a guide rail; two groups of heavy container assemblies 93 are arranged on the lower side of the material distribution machine hopper 92, and each group is provided with four heavy container assemblies 93, and the volumes of all the heavy container assemblies 93 are equal; the concrete pouring device 8 also includes a vibration component for compacting the concrete.

[0140] The concrete pouring device 8 is a system, and the above-mentioned components are only some of the executive components in this system. The system adopts automated precision material distribution equipment, and the control center 15 controls the material receiving and unloading, realizing fully automatic material calling, saving the manual material calling link and optimally assisting the material distribution link. The system consists of four parts: a material distribution machine, a material distribution machine trolley, a material distribution machine trolley bracket, and a precision metering system; concrete is distributed into the sleeper mold through a quantitative hopper with a weighing function. The material distribution is accurately connected by volume and weight. The paving type material distribution machine is one of the main production equipment of the production line and is the terminal equipment for conveying concrete. Its purpose is to distribute the concrete delivered from the mixing station to the component mold to be cast on the production line, so as to obtain the concrete prefabricated parts required by the design. The paving type material distribution machine is equipped with a load control system, which can accurately control the material distribution amount. Its position control system can cast the mold in the platform template in all directions. Its unique sensing and pouring control system can distribute the material uniformly in all directions. The volume of the hopper matches the mixing capacity of a general concrete mixer and can be seamlessly connected to the existing mixing equipment. The travel speed of the trolley and the truck of the paving machine can be adjusted and controlled, and an anti-collision parking mechanism is provided. The system is equipped with overload protection, flow control and other devices to ensure stable equipment performance, smooth operation, simple operation, safety and reliability.

[0141] The steam curing device 9 is an intelligent steam curing, capping and temperature control integrated system. After the mold 14 is hoisted into the curing pool, the automatic capping system uses a telescopic door to seal the mold. At the same time, the automated curing system automatically adjusts the steam flow and controls the steam curing temperature, and also generates a temperature line graph, realizing intelligent temperature control of steam curing. The temperature of the steam curing process is automatically collected, controlled and recorded.

[0142] The sleeper demoulding device 10 includes a truss outer frame component, which includes a truss crossbeam assembly 44. A storage assembly 45 for temporarily storing semi-finished products is provided at the lower side of the truss crossbeam assembly 44. A demoulding assembly 46 for separating the mold 14 and the sleeper 12 is also provided at the lower side of the truss crossbeam assembly 44. A mold clamping component 47 for conveying and flipping the semi-finished product is connected to the truss crossbeam assembly 44. The mold clamping component 47 is located on the upper side of the storage assembly 45 and can convey the semi-finished product to the demoulding assembly 46. Mold clamping component 47

[0143] The demoulding assembly 46 includes symmetrically arranged action parts, including a lifting platform 48, a demoulding platform 49 and a detection platform 50. The detection platforms 50 on both sides are arranged between the demoulding platforms 49 on both sides, and the demoulding platforms 49 on both sides are arranged between the lifting platforms 48 on both sides. Among them, the lifting platform 48 is provided with a first lifting part 51 for lifting the mold, the demoulding platform 49 is provided with a second lifting part 52 for lifting the semi-finished product, and the detection platforms 50 on both sides are provided with a plurality of detection parts 53 for detecting whether the mold 14 and the sleeper 12 are separated.

[0144] Preferably, a mold pillow conveying track 54 is provided between the inspection tables 50 on both sides, a sleeper transport component 55 and a mold transport component 56 are provided on the mold pillow conveying track 54, and a third lifting component 57 is provided on both the sleeper transport component 55 and the mold transport component 56.

[0145] The end where the storage component 45 is located on the sleeper demoulding device 10 is the semi-finished product input end and is connected to the steam curing device 9, the end where the sleeper transport component 55 is located is the finished product output end and is connected to the sleeper detection device 11, and the end where the mold transport component 56 is located is the mold output end and is connected to the mold cleaning device 1.

[0146] The first lifting member 51, the second lifting member 52 and the third lifting member 57 are all lifting cylinders. The cylinder bodies of the first lifting member 51 and the second lifting member 52 are fixed on the ground. When working, the upper end surface of the piston rod of the first lifting member 51 contacts the mold, and the upper end surface of the piston rod of the second lifting member 52 contacts the semi-finished sleeper. The cylinder body of the third lifting member 57 on the sleeper transport assembly 55 is fixed on the sleeper transport assembly 55, and the cylinder body of the third lifting member 57 on the mold transport assembly 56 is fixed on the mold transport assembly 56. When working, the upper end surfaces of their piston rods contact the sleeper and the mold respectively.

[0147] The demoulding process of the sleeper demoulding device 10 is as follows: the semi-finished product is first transported out of the steam curing device 9 through the track, and then directly transported to the storage assembly 45, and then the mold clamping component 47 clamps the semi-finished product and transports the semi-finished product from the storage assembly 45 to the demoulding assembly 46. During the transportation process, the semi-finished product needs to be flipped 180 degrees, and the mold 14 is turned from the bottom sleeper 12 to the top sleeper 12. After reaching the position of the demoulding assembly 46, the mold clamping component 47 releases the semi-finished product and returns to the upper side of the storage assembly 45 to prepare for the next transportation. The second lifting member 52 on the demoulding platform 49 continuously and rapidly pushes the semi-finished product upward, and then the second lifting member 52 is quickly withdrawn. After being ejected, the finished product will move downward under the action of gravity. The first lifting member 51 on the lifting platform 48 will prevent the mold 14 from continuing to move downward, but will not prevent the sleeper 12 from moving downward. Due to inertia, the mold 14 is separated from the sleeper 12, and the purpose of demoulding is achieved. At the same time, there are 4 detection parts 53 on each side of the detection table 50. The detection parts 53 are pressure sensors. When the sleepers 12 on the mold 14 are all detached, the pressure on the pressure sensor will be close or even equal. When the difference between the 8 pressure sensors under the 4 sleepers 12 is very small, it is determined that the demoulding is completed, and the second lifting part 52 stops working, and the first lifting part 51 lifts the mold 14 until it is completely detached from the sleeper 12. The sleeper transportation component 55 moves to the lower side of the sleeper 12, and the third lifting part 57 on its upper side lifts the sleeper 12 and transports it to the sleeper detection device 11. After the sleeper 12 is transported away, the mold 14 falls to the position before the sleeper 12 is transported away, and then the mold transportation component 56 moves to the lower side of the mold 14, and the third lifting part 57 on its upper side lifts the mold 14 and transports it to the mold cleaning device 1.

[0148] The sleeper detection device 11 includes a second laser image detection component with an image detection function, a sleeper identification component for detecting the sleepers 12, and a coding component for coding. The sleeper detection device 11 is an automated sleeper detection system. The above components are only some of the execution components in this system. It uses laser image detection technology to intelligently detect the outer dimensions of the sleepers, automatically identify the appearance quality and generate a test report. The sleeper information after the test is formed into a unique serial code and a two-dimensional code, which is directly printed on the sleeper through an automatic coding device.

[0149] The blow-injection buckle device 13 includes a sleeper transmission track 35 for conveying double-block sleepers. Both sides of the sleeper transmission track 35 are provided with a movable manipulator component 36. The driving component of the manipulator component 36 is electrically connected to the control center. The driving component is an electric motor. The upper end of the manipulator component 36 is provided with an integrated and rotatable base 37. The base 37 can rotate at any angle relative to the manipulator component 36. The base 37 is provided with a monitoring component that can monitor and locate. The monitoring component is a 3D camera 38. The 3D camera 38 can clearly see whether the waste residue in the casing hole is cleaned, oiled, and the specific situation of the buckle cover. The middle part of the camera can also be positioned with the middle part of the hole. The base 37 is provided with a blowing port 39 connected to the air supply component, and the base 37 is provided with an oil injection port 40 connected to the oil supply component. The base 37 is also provided with a buckle cover component 41 for buckling the casing hole. The upper surface of the base 37 is connected to the manipulator component 36, the cover assembly 41 is arranged on the lower surface of the base 37, and the monitoring assembly, the air blowing port 39 and the oil filling port 40 are all arranged on the side of the base 37. The air supply assembly is a blower, and the blower is connected to the air blowing port 39 through an air pipe, and the oil supply assembly is an oil supply tank, and the oil supply tank is connected to the oil filling port 40 through an oil pipe.

[0150] The positions of the 3D camera 38, the air blowing port 39, the oil filling port 40 and the cover assembly 41 relative to the base 37 are fixed. The 3D camera 38 first captures the position of the sleeve hole 75, and after being processed by the control center, the position information is transmitted to the air blowing port 39, the oil filling port 40 and the cover assembly 41 respectively. The air blowing port 39 can blow out a high-speed airflow and remove the waste residue in the sleeve hole 75. After the waste residue is removed, the oil filling port 40 injects oil into the sleeve hole 75, and the cover assembly 41 performs the cover operation on the sleeve hole 75. The control center controls the manipulator component 36 to operate freely, and at the same time, each execution component on the base 38 is also controlled by the control center, so that the device is fully automated, and the central control adopts the existing technology.

[0151] Preferably, the cover assembly 41 includes a pick-up member that matches the inner hole of the cover end, and a through hole is provided inside the pick-up member, and a pressing member that can move along the through hole and is used to press the cover into the sleeve hole 75 on the sleeper is provided in the through hole. The input end of the pressing member is connected to the piston on the cylinder, and the cylinder body of the cylinder is arranged inside the base 37. The pick-up member is a pick-up rod, which can be inserted into the hole on the cover, so as to achieve the purpose of picking up the cover, and the pressing member is a pressing rod, which is arranged in the hole inside the pick-up rod, and the pressing rod can reciprocate relative to the pick-up rod. When the cover is attached, the pressing rod moves in the direction of the cover, so that the cover can be pushed out from the pick-up rod, and the cover can be pressed on the entrance of the sleeve hole 75. During the whole working process, the 3D camera 38 monitors the whole process and facilitates positioning.

[0152] The blow-injection buckle device 13 is an intelligent integrated equipment system for blowing, oiling and capping. The above-mentioned components are only some of the executive components in this system. The system uses two industrial robots, two sets of 3D vision systems, two sets of cover screening mechanisms and other equipment. When four sleepers arrive at the station. The robot drives the 3D camera to take pictures of the sleepers, identify the XY coordinate offset and depth information of the casing hole, and the six-axis robot grabs the cover from the cover screening machine and places it above the casing hole. The clamping device presses the cover into the casing hole. The oil injection system uses a high-precision detection device (existing technology) to ensure the stability and consistency of the oil injection amount.

[0153] The sleeper cache maintenance device 16 is an intelligent sleeper cache maintenance equipment. A constant temperature and constant humidity intelligent maintenance system is adopted in the cache maintenance workshop. The temperature and humidity are adjusted and digitally displayed by intelligent control instruments in real time. The operation of the cache workshop is monitored in real time through a remote terminal. The intelligent sleeper cache maintenance workshop has realized the transformation from manual watering maintenance to intelligent and information-based sleeper maintenance, thereby improving the sleeper maintenance level.

[0154] The structures and connection relationships of the parts, assemblies and components not described in detail in each device are based on the existing technology.

[0155] The control center 15 includes a start button for starting the production system and a stop button for shutting down the production line. The control center 15 is an intelligent control system that adopts a modular embedded information integration mode, which includes the production line intelligent control system, MES manufacturing execution system, PHM fault prediction and health management system, SCADA data acquisition and monitoring control system, and sleeper automation detection system for integration and deep integration, to establish a sleeper production digital workshop, and initially realize the digital and intelligent management and control of sleeper prefabrication "people, machines, materials, methods, and environment", so that the equipment in the intelligent workshop can run more efficiently, the process connection and transformation can be smoother, and the information processing can be more timely, so as to achieve the purpose of predicting and monitoring the equipment status, and the operator can centrally control the entire process in the background, reduce the equipment failure rate, improve the sleeper production efficiency, and reduce the number of operators. The technologies included in the intelligent control are all existing technologies.

[0156] The production method of the automatic and unmanned production system of the double-block sleeper comprises the following steps:

[0157] 1. Press the start button to start the semi-finished product production line with automatic circulation function and the finished product production line for producing sleepers at the same time.

[0158] 2. The concrete residue in the inner cavity of the mold 14 is cleaned in the mold cleaning device 1 with a dual screening function. The specific steps are as follows:

[0159] 1) The mold 14 is transported to the upper side of the sand return funnel 19 through the roller conveyor 20;

[0160] 2) The air compressor ejects high-speed airflow through the air inlet 42;

[0161] 3) The corundum in the sand box 23 is mixed with the high-speed airflow in the corundum nozzle 18 through the sand inlet 30;

[0162] 4) The high-speed airflow is mixed with corundum and sprayed into the inner cavity of the mold 14 through the injection port 43 to clean the concrete slag;

[0163] 5) After the diamond dust is mixed with the concrete residue, it falls on the diamond dust screen 28 for the first filtration;

[0164] 6) The filtered corundum and the concrete residue enter the sand box 23 through the second sand return auger 26, the corundum conveyor belt 27 and the first sand return auger 25;

[0165] 7) The second filtration is performed in the sandbox 23, and the filtered corundum is stored in the sandbox 23 and can be used in the next cycle, and the concrete residue is discharged through the discharge pipe 17;

[0166] 8) After the set time, the cleaning work is completed.

[0167] 3. In the mold detection device 2, the first laser image detection component detects whether the inner cavity of the mold 14 is damaged. If the inner cavity of the mold 14 is not damaged, the mold 14 enters the sleeve spiral rib installation and re-inspection device 4; if the inner cavity of the mold 14 is damaged, the mold selection component pushes the mold 14 out of the production line, and the mold identification component will identify the mold number and generate a first inspection report.

[0168] 4. In the release agent spraying device 3, the release agent spraying component sprays the release agent on the inner cavity of the mold 14. At the same time, the flipping component flips the mold 14 180 degrees so that the inner cavity of the mold 14 faces upward.

[0169] 5. In the casing spiral rib installation and re-inspection device 4, the casing and the spiral rib are combined into a casing assembly, and the casing assembly is installed on the casing assembly installation position 77 in the inner cavity of the mold 14. The first re-inspection component 88 monitors the installation position of the casing assembly. The specific steps are as follows:

[0170] 1) The casing sorting component 83 moves the casing from the casing storage component 80 to the upper side of the casing spiral rib conveyor belt 82;

[0171] 2) The spiral rib installation component 84 moves the spiral rib from the coil spring component 79 to the sleeve and preliminarily assembles it;

[0172] 3) The casing and spiral rib conveyor belt 82 conveys the casing and spiral rib to the casing and spiral rib fastening component 81 for screwing and assembly;

[0173] 4) The casing assembly manipulator 90 moves the assembled casing assembly from the casing spiral rib fastening component 81 to the casing spiral rib placement table 86;

[0174] 5) The casing spiral rib installation component 87 moves the casing assembly from the casing spiral rib placement table 86 to the casing assembly installation position 77 in the mold 14 and assembles it;

[0175] 6) The first re-inspection component 88 monitors whether the sleeve assembly is correctly installed on the sleeve assembly installation position 77 in the inner cavity of the mold 14. If it is monitored that the sleeve assembly is correctly installed on the sleeve assembly installation position 77, the mold 14 enters the truss stirrup installation and re-inspection device 6; if it is monitored that the sleeve assembly is not correctly installed on the sleeve assembly installation position 77, the first re-inspection component 88 transmits the position information of the sleeve assembly and the sleeve assembly installation position to the control center 15, and the control center 15 transmits the information to the sleeve spiral reinforcement installation component 87, and the sleeve spiral reinforcement installation component 87 corrects the position of the sleeve assembly. After the correction is completed, the mold 14 enters the truss stirrup installation and re-inspection device 6.

[0176] 6. In the truss stirrup installation and re-inspection device 6, the second truss clamping jaw 68 clamps the truss stirrup 74 and installs the truss stirrup 74 at the truss stirrup installation position on the mold 14, and the second re-inspection component monitors whether the truss stirrup 74 is correctly installed at the truss stirrup installation position on the mold 14. If it is monitored that the truss stirrup 74 is correctly installed at the truss stirrup installation position, the mold 14 enters the concrete pouring device 8; if it is monitored that the truss stirrup 74 is not correctly installed at the truss stirrup installation position, the second re-inspection component transmits the position information of the truss stirrup 74 and the truss stirrup installation position to the control center 15, and the control center 15 transmits the information to the second truss clamping jaw 68, and the second truss clamping jaw 68 corrects the position of the truss stirrup 74. After the correction is completed, the mold 14 enters the concrete pouring device 8.

[0177] Before installing the truss stirrups, the truss stirrups are assembled in the truss stirrup assembly device 7, and the specific steps are as follows:

[0178] 1) The first truss clamping claw 62 moves the steel truss from the truss storage platform 65 to the truss receiving platform 63, and turns the steel truss 180° during the movement;

[0179] 2) The truss conveying platform 64 moves the truss receiving platform 63 equipped with the steel truss to one side of the input end of the truss conveyor belt 69;

[0180] 3) The third truss clamping claw member 70 clamps the steel truss and places it on the truss conveyor belt 69, and the truss conveyor belt 69 conveys the steel truss to the truss stirrup assembly component;

[0181] 4) The second truss clamping claw member 68 on the truss stirrup assembly component clamps the steel truss conveyed by the truss conveyor belt 69;

[0182] 5) The hook is transported to the truss stirrup assembly component, and the truss stirrup installation component 73 installs the hook on the steel truss;

[0183] 6) The stirrup conveying assembly 59 takes the steel stirrups out of the steel bar funnel assembly 60 and places them on the stirrup conveying roller 58. The steel stirrups on the stirrup conveying roller 58 are conveyed to the truss stirrup assembly component through the stirrup conveyor belt 66. The truss stirrup installation assembly 73 installs the steel stirrups on the hooks on the steel bar truss.

[0184] 7) The second truss clamping claw 68 on the truss stirrup assembly component transports the truss stirrup 74 assembled from the steel bar truss, hooks and steel stirrups to the truss stirrup installation and re-inspection device 6 .

[0185] 7. In the concrete pouring device 8, the pouring component pours the concrete into the inner cavity of the mold 14, and the vibrating component compacts the poured concrete.

[0186] 8. Steam-curing the semi-finished product in the steam curing device 9.

[0187] 9. The mold 14 and the sleeper 12 are separated in the sleeper demoulding device 10. The specific steps are as follows:

[0188] 1) conveying the semi-finished product to the storage assembly 45;

[0189] 2) The mold clamping component 47 clamps the semi-finished product from the storage component 45 and conveys it to the demoulding component 46. During the conveying process, the mold clamping component 47 turns the semi-finished product 180°;

[0190] 3) The mold clamping component 47 places the semi-finished product on the demoulding component 46 and then returns to the upper side of the storage component 45 and stops conveying the next semi-finished product;

[0191] 4) The second lifting member 52 on the demoulding assembly 46 continuously and rapidly lifts and lowers the semi-finished product, and the first lifting member 51 prevents the mold 14 from falling but does not prevent the sleeper 12 from falling;

[0192] 5) The detection member 53 on the detection table 50 detects whether the sleeper 12 is separated from the mold 14. If it is detected that the sleeper 12 is not separated from the mold 14, the second lifting member 52 continues to work and the mold clamping member 47 does not convey the semi-finished product. If it is detected that all the sleepers 12 are separated from the mold 14, the first lifting member 51 pushes the mold 14 upward and keeps a certain distance from the upper side of the sleeper 12;

[0193] 6) S9.6: The sleeper transport assembly 55 enters the lower side of the sleeper 12 through the sleeper mold conveying track 54, and the third lifting member 57 on the sleeper transport assembly 55 pushes the sleeper 12 upward. When the sleeper 12 is separated from the demoulding assembly 46, the sleeper transport assembly 55 transports the sleeper 12 to the sleeper detection device 11;

[0194] 7) After the sleeper 12 is transported, the first lifting member 51 descends, and the mold 14 on the upper side thereof moves downward. At the same time, the mold transport assembly 56 enters the lower side of the mold 14, and the third lifting member 57 on the mold transport assembly 56 pushes the mold 14 upward. When the mold 14 is separated from the demolding assembly 46, the mold transport assembly 56 transports the sleeper 12 to the mold cleaning device 1;

[0195] 8) After the mold 14 is transported, the mold clamping component 47 starts to transport the semi-finished product again.

[0196] 10. In the sleeper detection device 11, the second laser image detection component detects the outer dimensions of the sleeper 12, and the sleeper identification component 12 detects the appearance quality of the sleeper 12, and inputs the detected outer dimension information and the detected appearance quality information to the control center 15. The control center 15 generates a second detection report based on the information, and forms a serial code and a two-dimensional code from the second detection report, and then transmits the serial code and two-dimensional code information to the coding component, which prints the serial code and the two-dimensional code on the label 76 of the sleeper 12.

[0197] 11. In the blowing and injecting buckle device 13, the 3D camera 38 first identifies the position information of the casing hole 75 on the sleeper 12 and transmits the position information to the control center 15, and the control center 15 then transmits the information to the manipulator component 36, and the manipulator component 36 adjusts the air port 39 to a position opposite to the casing hole 75, and the air blowing assembly blows air to the casing hole 75 through the air port 39 and removes concrete residue. When the concrete residue in the casing hole 75 is removed; the manipulator component 36 adjusts the oil filling port 40 to a position opposite to the casing hole 75, and the oil filling assembly injects oil into the casing hole 75 through the oil filling port 40. When the casing hole 75 is injected with oil; the buckle cover assembly 41 on the manipulator component 36 grabs the buckle cover and inserts it into the casing hole 75.

[0198] 12. The sleepers 12 are maintained at a constant temperature and humidity in the sleeper buffer maintenance device 16 .

[0199] 13. Press the stop button to end the operation of the semi-finished product production line and the finished product production line.

[0200] The sleeper production process is as follows: cleaning mold---mold inspection---spraying mold release agent---installation of double-block sleeper casing, stirrups and trusses---concrete pouring---steam curing---sleeper demoulding---finished product inspection--sleeper maintenance. The sleeper production line will achieve automation, intelligence and unmanned functions at each workstation in accordance with the construction goal of intelligent and unmanned operation.

[0201] The length and width of the production workshop are 96m×48m, with sleeper production workshop and steel bar production workshop separated from each other, covering an area of ​​24m×96m. The workshop is built with color steel shed to form a closed space. With production process as the main line and sleeper workshop as the center, combined with the construction requirements of fully automated unmanned production line, the functional areas of raw material storage, concrete mixing, steel bar processing, sleeper production, and sleeper buffer workshop are arranged in a line to achieve seamless connection between material transportation and production.

[0202] 1. Raw material reserves

[0203] Silos are used to store sand and gravel raw materials. In order to reduce environmental pollution, closed silos are used. The top of the silo is equipped with an atomization dust reduction system to reduce dust in the silo. The length and width of the silo are 55.4m×42.5m, and there are 27 steel structure columns supporting the lower side. The steel structure is 1.5m*1.5m*1.5m, and the embedded parts are 0.6m*0.6m*0.6m. The secondary casting method is adopted; at the same time, 6 aggregate silos are set up, including 2 medium sand silos, 2 5-10mm crushed stone silos, and 2 10-20mm crushed stone silos. There is one silo for each material, one for qualified and one for inspection. The storage capacity of each silo is more than 350m³, which meets the needs of normal production.

[0204] 2. Concrete mixing

[0205] Concrete mixing uses HZQ120F8 Sany forced mixer, which occupies an area of ​​20 m×23.7 m and is equipped with 5 powder tanks (3 cement tanks, 2 admixture tanks, each with a storage capacity of 200t), 2 water reducer tanks, and 1 water reservoir, which can meet the production demand of 1,600 sleepers per day. The tank body and important structures are built with color steel plates for protection and are connected to the workshop through a steel structure transportation channel. At the same time, a 7-level sedimentation tank is set up next to it for recycling and sedimentation of sewage in the mixing station and workshop. At the same time, in order to ensure construction under special environmental conditions, a constant temperature water circulation system is set up next to the water reservoir to automatically control the water temperature to meet the requirements of heating and cooling.

[0206] 3. Steel bar processing

[0207] The steel production workshop is equipped with a truss processing production line, CNC stirrup bending machine, stirrup welding, steel raw material storage area (12m×12m), semi-finished product and finished product storage area (about 780m 2), which can meet the normal steel bar storage and processing supply requirements.

[0208] 4. Sleeper production

[0209] The sleeper production workshop is equipped with a fully automatic sleeper ring production line, an intelligent control center and an observation channel.

[0210] The fully automatic rail sleeper ring production line uses highly automatic and intelligent means, reasonable layout, and creates the best production line. The production line is divided into demoulding station, mold cleaning station, spraying demoulding agent station, installation of casing spiral reinforcement station, installation of truss stirrup station, concrete pouring station, entry and exit buffer station, steam curing station, kiln cache station, inspection station, oil filling and capping station, and rail sleeper stacking station. In order to protect the workshop environment, a transparent room is set up separately for spraying demoulding agent station, and two recycling equipments are installed; the steam curing station is equipped with 12 curing pools, each of which is 3.8 m×3.8 m×4m, which can store 9×2 molds, and a temperature control system is installed to collect the curing temperature every 10 minutes.

[0211] The intelligent control center and observation channel are arranged overhead, 3.8m above the ground. The observation channel is 3m×3.8m wide and high, and is arranged in a semi-circular pattern around the production line. The corresponding workstations can be seen through the glass curtain wall of the channel, and each workstation can be observed closely while ensuring safety.

[0212] The length, width and height of the intelligent control center workshop are 24m×12m×3.8m respectively. It is equipped with a VR experience hall (for 3D simulation demonstration experience of construction safety), an information processing center (for collecting data such as raw materials, sleeper prefabrication process, finished sleepers, etc. to control the quality of sleeper prefabrication and traceability of sleeper prefabrication information), and a real-time monitoring center (real-time monitoring of the production line to ensure normal production). The central control room and sightseeing passage are built with high-quality wooden boards, supported by steel structures, and there are no burns at the welding points.

[0213] 4. Sleeper Cache

[0214] The sleeper buffer workshop is a secondary maintenance shed, with a length and width of 48m×48m, supported by 26 steel structure columns. The structural foundation of each column support is 1.5m*1.5m*1.5m reinforced concrete, and the embedded parts are 0.4m*0.4m*0.02m in size, which are cast in one time. The maintenance shed can meet the storage capacity of 10d sleepers. The roof is equipped with two systems, atomization and spraying, which can adjust the temperature by water temperature, and is used for automatic maintenance of sleeper buffer insulation and moisture retention.

[0215] The production lines are laid out according to the production system, and the conveyor tracks between the devices are arranged according to the production lines. Based on the conveyor tracks, the sleeper prefabrication device is divided according to the functional areas and workstations, and the sleeper prefabrication device is organically split. The fully automated device on each workstation forms a modular unit, and the modular units are organically interconnected to reduce the operation time of installing / disassembling the device and reduce costs. On the basis of device standardization, the overall functional size of the device, the installation / disassembly work space, transportation conditions and other factors are comprehensively considered, and the device is integrated into several functional modular units. The modular units are connected by functional connectors to achieve rapid installation / disassembly of the device. Finally, loading and unloading, handling, storage and transportation are carried out based on the modular units to achieve standardization and modularization of sleeper prefabrication devices.

[0216] The conveyor track between the devices is a basic chain conveyor track: including rollers, frames, supporting foundations, drivers, positioning guards, guide rails, etc. It is a roller-arranged sprocket-driven conveyor, which is mainly used to transport empty molds or molds after casting to the location of the corresponding device.

[0217] The above is only a preferred embodiment of the present invention. It should be understood that the present invention is not limited to the form disclosed herein, and should not be regarded as excluding other embodiments, but can be used in various other combinations, modifications and environments, and can be modified within the scope of the concept described herein through the above teachings or the technology or knowledge of the relevant field. The changes and modifications made by those skilled in the art shall not deviate from the spirit and scope of the present invention, and shall be within the scope of protection of the claims attached to the present invention.

Claims

1. An automated, unmanned production system for double-block sleepers, comprising a mold detection device (2), a mold release agent spraying device (3), a casing spiral reinforcement installation and re-inspection device (4), a truss stirrup installation and re-inspection device (6), a truss stirrup assembly device (7), a concrete pouring device (8) with a precision material distribution component (5), a steam curing device (9), a sleeper detection device (11), a blow-injection buckle device (13), a control center (15) and a sleeper buffer curing device (16), characterized in that: It also includes a mold cleaning device (1) with a dual screening function and a sleeper demoulding device (10) with a multi-directional conveying function; The control center (15) is electrically connected to the execution components of each of the above-mentioned devices; The sleeper demoulding device (10) is provided with a semi-finished product input end for conveying the semi-finished product to the sleeper demoulding device (10), a finished product output end for conveying the sleeper (12) to the sleeper detection device (11), and a mold output end for conveying the mold (14) to the mold cleaning device (1); The mold cleaning device (1), mold detection device (2), mold release agent spraying device (3), casing spiral reinforcement installation and re-inspection device (4), truss stirrup installation and re-inspection device (6), concrete pouring device (8), steam curing device (9) and sleeper demoulding device (10) are sequentially connected to form an automatic circulation semi-finished product production line; The mold cleaning device (1), the mold detection device (2), the mold release agent spraying device (3), the casing spiral reinforcement installation and re-inspection device (4), the truss stirrup installation and re-inspection device (6), the concrete pouring device (8), the steam curing device (9), the sleeper demoulding device (10), the sleeper detection device (11), the injection button blowing device (13) and the sleeper buffer curing device (16) are sequentially connected to form a finished product production line for producing sleepers (12); The truss stirrup installation and re-inspection device (6) is connected to the output end of the truss stirrup assembly device (7); The mold cleaning device (1) comprises a diamond sand spray head (18) for mold cleaning, wherein the diamond sand spray head (18) is arranged on the upper side of a sand return funnel (19), a roller conveyor (20) for conveying the mold is arranged on the upper side of the sand return funnel (19), a sand blasting shell (21) connected to the sand return funnel (19) is arranged on the upper side of the roller conveyor (20), a vibrating screen assembly (22) and two sand boxes (23) are arranged on the upper plane of the sand blasting shell (21), and the two sand boxes (23) are respectively located at The sand box (23) is connected to the vibrating screen assembly (22) via a sand feeding auger (24); the input end of the vibrating screen assembly (22) is connected to a first sand returning auger (25); the vibrating screen assembly (22) is also provided with a discharge pipe (17) for removing concrete residues; the sand returning funnel (19) is provided with a second sand returning auger (26); the first sand returning auger (25) and the second sand returning auger (26) are connected via a corundum conveyor belt (27); The return sand funnel (19) is also provided with a diamond sand screen (28) for screening diamond sand, a fixing rod (29) is provided on the upper side of the diamond sand screen (28), a plurality of diamond sand spray heads (18) are mounted on the fixing rod (29), and the diamond sand spray heads (18) are also provided with a sand inlet (30), an air inlet (42) and an injection port (43), the sand inlet (30) is connected to the sand box (23), and the air inlet (42) is connected to an external air compressor; A dust removal pipeline (31) is also provided on the upper plane of the sandblasting housing (21); the input end of the dust removal pipeline (31) is connected to the interior of the sandblasting housing (21); the output end of the dust removal pipeline (31) is provided with a dust removal box (32); the dust removal box (32) is provided with a filter rotating motor (33) for extracting dust from the interior of the sandblasting housing (21); The first sand-returning auger (25), the second sand-returning auger (26) and the sand-returning funnel (19) are all provided with an auger rotating motor (34) for providing power for conveying corundum; The casing spiral rib installation and re-inspection device (4) comprises a coil spring component (79) for processing the spiral rib, a casing storage component (80) for storing the casing, and a casing spiral rib fastening component (81) for screwing the spiral rib and the casing into a casing assembly, wherein the casing spiral rib fastening component (81) is arranged between the coil spring component (79) and the casing storage component (80), and a casing spiral rib conveyor belt (82) is arranged on the lower side of the casing spiral rib fastening component (81). A sleeve sorting component (83) is provided between the sleeve spiral rib fastening component (81) and the sleeve storage component (80) for moving the sleeve from the sleeve storage component (80) to the upper side of the sleeve spiral rib conveyor belt (82); and a spiral rib installation component (84) is provided between the sleeve spiral rib fastening component (81) and the coil spring component (79) for moving the spiral rib from the coil spring component (79) to the upper side of the sleeve spiral rib conveyor belt (82); The casing spiral rib installation and re-inspection device (4) further comprises a casing assembly installation frame (85), the casing assembly installation frame (85) being provided with a casing spiral rib installation component (87) for moving the casing assembly from the casing spiral rib placement table (86) to the mold (14), the casing spiral rib installation component (87) being provided with a first re-inspection component (88) for detecting the casing assembly, a mold conveying roller (89) for conveying the mold (14) being provided at the lower side of the casing spiral rib installation component (87), the casing spiral rib placement table (86) being provided between the casing assembly installation frame (85) and the casing spiral rib fastening component (81), and the casing spiral rib fastening component (81) being provided with a casing assembly robot (90) for moving the casing assembly from the casing spiral rib fastening component (81) to the casing spiral rib placement table (86); The truss stirrup assembly device (7) comprises a truss stirrup assembly component, and also comprises a truss feeding component and a stirrup feeding component arranged on both sides of the truss stirrup assembly component; The stirrup feeding component comprises a stirrup conveying roller (58) for conveying steel stirrups, and also comprises a stirrup conveying assembly (59) for transferring the steel stirrups from the steel bar funnel assembly (60) to the stirrup conveying roller (58), the output end of the stirrup conveying roller (58) being connected to the truss stirrup assembly component; The truss loading component comprises a truss loading outer frame assembly (61), the truss loading outer frame assembly (61) is symmetrically provided with a first truss clamping claw member (62) for clamping, flipping and moving the steel bar truss, the lower side of the first truss clamping claw member (62) is provided with a truss receiving platform (63) for supporting the steel bar truss, the lower side of the truss receiving platform (63) is provided with a truss conveying platform (64) for conveying the truss receiving platform (63), the input side of the truss conveying platform (64) is provided with a movable truss storage platform (65), and the upper end of the truss receiving platform (63) is provided with an inverted triangle for preventing the steel bar truss from deflecting and cooperating with the truss stirrup (74); The truss stirrup assembly component comprises a stirrup conveyor belt (66) connected to the output end of the stirrup conveying roller (58) and used for conveying the steel stirrups; a truss stirrup assembly outer frame (67) is provided at the output end of the stirrup conveyor belt (66); a second truss clamping claw member (68) for clamping the steel truss is provided on the truss stirrup assembly outer frame (67); the truss stirrup assembly outer frame (67) is connected to the output end of the truss conveyor belt (69); the truss conveyor belt (69) and the stirrup conveyor belt (66) are arranged opposite to each other; one side of the input end of the truss conveyor belt (69) contacts the output end of the truss conveying platform (64); and a third truss clamping claw member (70) for conveying the steel truss from the truss receiving platform (63) to the truss conveyor belt (69) is provided on the upper side of the truss conveyor belt (69); The truss stirrup assembly component further comprises a hook clamping member (71) for clamping a hook, and a hook conveyor belt (72) for transporting the hook clamping member (71), the output end of the hook conveyor belt (72) being located at the lower side of the second truss clamping claw member (68), and the input end of the hook conveyor belt (72) being provided with a hook storage assembly for storing the hook; The truss stirrup assembly component also includes a truss stirrup installation component (73) for installing the hook on the steel truss, and the truss stirrup installation component (73) also installs the steel stirrup on the hook. After the hook and the steel stirrup are installed on the steel truss, a truss stirrup (74) is formed; The output end of the truss stirrup assembly device (7) is the second truss clamping claw member (68), and the second truss clamping claw member (68) clamps the truss stirrup (74) and moves on the truss stirrup assembly outer frame (67), and puts the truss stirrup (74) into the truss stirrup installation and re-inspection device (6); The concrete pouring device (8) comprises a feeding component (91) for conveying concrete from a stirring component to a precise material distribution component (5); the precise material distribution component (5) comprises a material distribution machine hopper (92) having a quantitative material loading function; a plurality of weighing container assemblies (93) are provided on the lower side of the material distribution machine hopper (92); a plurality of closable first material discharge ports (94) are provided at the bottom of the material distribution machine hopper (92); each of the first material discharge ports (94) is provided correspondingly to the positive end of the weighing container assembly (93); At the top, a second material discharge port (95) that can be closed is arranged at the lower side of the weighing container assembly (93), a material discharge port driving assembly (96) for opening / closing the second material discharge port (95) is arranged on the second material discharge port (95), the outlet of the second material discharge port (95) is arranged at the upper side of the mold cavity, the precise material distribution component (5) is provided with a stirring assembly (97) for preventing concrete from coagulating, and the precise material distribution component (5) and the feeding component (91) are both arranged on a bracket with a guide rail; Two groups of the heavy container assemblies (93) are arranged on the lower side of the material placing machine hopper (92), each group being provided with four heavy container assemblies (93), and the volumes of all the heavy container assemblies (93) are equal; The concrete pouring device (8) further comprises a vibrating component for compacting the concrete; The rail sleeper demoulding device (10) comprises a truss outer frame component, the truss outer frame component comprises a truss crossbeam assembly (44), a storage assembly (45) for temporarily storing semi-finished products is arranged on the lower side of the truss crossbeam assembly (44), a demoulding assembly (46) for separating the mold (14) and the rail sleeper (12) is also arranged on the lower side of the truss crossbeam assembly (44), a mold clamping component (47) for conveying and turning over the semi-finished products is connected to the truss crossbeam assembly (44), and the mold clamping component (47) is located on the upper side of the storage assembly (45) and can convey the semi-finished products to the demoulding assembly (46); The demoulding assembly (46) comprises symmetrically arranged action parts, the action parts comprising a lifting platform (48), a demoulding platform (49) and a detection platform (50), the detection platforms (50) on both sides are arranged between the demoulding platforms (49) on both sides, and the demoulding platforms (49) on both sides are arranged between the lifting platforms (48) on both sides; The lifting platform (48) is provided with a first lifting member (51) for lifting the mold, the demoulding platform (49) is provided with a second lifting member (52) for lifting the semi-finished product, and the detection platforms (50) on both sides are provided with a plurality of detection members (53) for detecting whether the mold (14) and the sleeper (12) are separated. A mold pillow conveying track (54) is provided between the inspection tables (50) on both sides, a sleeper conveying assembly (55) and a mold conveying assembly (56) are provided on the mold pillow conveying track (54), and a third lifting member (57) is provided on both the sleeper conveying assembly (55) and the mold conveying assembly (56); The end of the sleeper demoulding device (10) where the storage component (45) is located is a semi-finished product input end and is connected to the steam curing device (9); the end where the sleeper transport component (55) is located is a finished product output end and is connected to the sleeper detection device (11); and the end where the mold transport component (56) is located is a mold output end and is connected to the mold cleaning device (1); The first lifting member (51), the second lifting member (52) and the third lifting member (57) are all lifting cylinders; The blow-injection buckle device (13) comprises a sleeper transfer track (35) for conveying double-block sleepers, both sides of the sleeper transfer track (35) are provided with a manipulator component (36) with a motion function, and the upper end of the manipulator component (36) is provided with an integrated and rotatable base (37); The base (37) is provided with a 3D camera (38) capable of monitoring and positioning, an air blowing port (39) connected to an air supply component, an oil filling port (40) connected to an oil supply component, and a cover assembly (41) for covering the sleeve hole; The upper surface of the base (37) is connected to the manipulator component (36), the buckle cover assembly (41) is arranged on the lower surface of the base (37), and the 3D camera (38), the air blowing port (39) and the oil filling port (40) are all arranged on the side of the base (37); The buckle cover assembly (41) comprises a pick-up piece matched with the inner hole of the end of the buckle cover, the pick-up piece is provided with a through hole inside, and a pressing piece is provided in the through hole which can move along the through hole and is used to press the buckle cover into the sleeve hole on the sleeper; The input end of the pressing member is connected to a piston on a cylinder, and the cylinder body of the cylinder is arranged inside the base (37); The control center (15) includes a start button for starting the production system and a stop button for shutting down the production line; The mold (14) is provided with a sleeve assembly installation position (77), a truss stirrup installation position (78) and a mold number; The mold detection device (2) comprises a first laser image detection component with an image detection function, a mold identification component for identifying a mold number, and a mold selection component for selecting a damaged mold; The mold release agent spraying device (3) comprises a mold release agent spraying component filled with a mold release agent and a flipping component used to flip the mold (14) so ​​that its inner cavity faces upward; The truss stirrup installation and re-inspection device (6) comprises a second re-inspection component for inspecting the truss stirrup (74) and the truss stirrup installation position; The sleeper detection device (11) comprises a second laser image detection component having an image detection function, a sleeper identification component for detecting the sleeper (12), and a coding component for coding.

2. The production method of the production system according to claim 1, characterized in that: The following steps are involved: S1: Press the start button to start the semi-finished product production line with automatic circulation function and the finished product production line for producing sleepers at the same time; S2: cleaning the concrete residue in the inner cavity of the mold (14) in the mold cleaning device (1) having a dual screening function; S3: In the mold detection device (2), the first laser image detection component detects whether the inner cavity of the mold (14) is damaged. If the inner cavity of the mold (14) is not damaged, the mold (14) enters the sleeve spiral rib installation and re-inspection device (4); if the inner cavity of the mold (14) is damaged, the mold selection component pushes the mold (14) out of the production line, and the mold identification component identifies the mold number and generates a first detection report; S4: In the mold release agent spraying device (3), the mold release agent spraying component sprays the mold release agent on the inner cavity of the mold (14), and at the same time, the flipping component flips the mold (14) by 180 degrees so that the inner cavity of the mold (14) faces upward; S5: In the sleeve spiral rib installation and re-inspection device (4), the sleeve and the spiral rib are combined into a sleeve assembly, and the sleeve assembly is installed on the sleeve assembly installation position (77) in the inner cavity of the mold (14), and the first re-inspection component (88) monitors the installation position of the sleeve assembly; S6: In the truss stirrup installation and re-inspection device (6), the second truss clamping claw member (68) clamps the truss stirrup (74) and installs the truss stirrup (74) at the truss stirrup installation position on the mold (14), and the second re-inspection component monitors whether the truss stirrup (74) is correctly installed at the truss stirrup installation position on the mold (14). If it is monitored that the truss stirrup (74) is correctly installed at the truss stirrup installation position, the mold (14) enters the concrete pouring device. If it is detected that the truss stirrup (74) is not correctly installed on the truss stirrup installation position, the second re-inspection component transmits the position information of the truss stirrup (74) and the truss stirrup installation position to the control center (15), and the control center (15) transmits the information to the second truss clamping member (68), and the second truss clamping member (68) corrects the position of the truss stirrup (74). After the correction is completed, the mold (14) enters the concrete pouring device (8); Wherein, before installing the truss stirrups, the truss stirrups are assembled in the truss stirrup assembly device (7); S7: In the concrete pouring device (8), the pouring component pours concrete into the inner cavity of the mold (14), and the vibrating component performs a compacting operation on the poured concrete; S8: steam-curing the semi-finished product in the steam curing device (9); S9: performing a separation operation of the mold (14) and the sleeper (12) in the sleeper demoulding device (10); S10: In the sleeper detection device (11), the second laser image detection component detects the external dimensions of the sleeper (12), the sleeper identification component (12) detects the appearance quality of the sleeper (12), and transmits the detected external dimension information and the detected appearance quality information to the control center (15), the control center (15) generates a second detection report based on the information, and converts the second detection report into a serial code and a two-dimensional code, and then transmits the serial code and two-dimensional code information to the coding component, and the coding component prints the serial code and two-dimensional code on the label (76) of the sleeper (12); S11: In the blow-injection buckle device (13), the 3D camera (38) first identifies the position information of the sleeve hole (75) on the rail sleeper (12) and transmits the position information to the control center (15), and the control center (15) then transmits the information to the manipulator component (36), and the manipulator component (36) adjusts the blowing port (39) to a position relative to the sleeve hole (75), and the blowing component blows the sleeve hole (75) through the blowing port (39). The sleeve hole (75) is blown to remove concrete slag. When the concrete slag in the sleeve hole (75) is completely removed, the mechanical hand component (36) adjusts the oil filling port (40) to a position relative to the sleeve hole (75). The oil filling component fills the sleeve hole (75) with oil through the oil filling port (40). When the oil filling of the sleeve hole (75) is completed, the buckle cover component (41) on the mechanical hand component (36) grabs the buckle cover and inserts it into the sleeve hole (75); S12: performing constant temperature and constant humidity maintenance on the sleeper (12) in the sleeper buffer maintenance device (16); S13: Press the stop button to end the operation of the semi-finished product production line and the finished product production line.

3. The production method according to claim 2, characterized in that: The production method of S2 comprises the following sub-steps: S2.1: transporting the mold (14) to the upper side of the sand return hopper (19) via a roller conveyor (20); S2.2: The air compressor ejects high-speed airflow through the air inlet (42); S2.3: The corundum in the sand box (23) is mixed with the high-speed airflow in the corundum nozzle (18) through the sand inlet (30); S2.4: The high-speed airflow is mixed with corundum and sprayed into the inner cavity of the mold (14) through the injection port (43) to clean the concrete residue; S2.5: The diamond dust mixed with the concrete residue falls onto the diamond dust screen (28) for the first filtration; S2.6: The filtered corundum and the concrete residue pass through the second sand return auger (26), the corundum conveyor belt (27) and the first sand return auger (25) and enter the sand box (23); S2.7: performing a second filtration in the sandbox (23), wherein the filtered corundum is stored in the sandbox (23) and can be used in the next cycle, and the concrete residue is discharged through the discharge pipe (17); S2.8: After the set time, the cleaning work is completed; The production method of S5 comprises the following sub-steps: S5.1: the casing sorting component (83) moves the casing from the casing storage component (80) to the upper side of the casing spiral rib conveyor belt (82); S5.2: The spiral rib installation component (84) moves the spiral rib from the coil spring component (79) to the sleeve for preliminary assembly; S5.3: The casing and spiral rib conveyor belt (82) conveys the casing and spiral rib to the casing and spiral rib fastening component (81) for screwing and assembly; S5.4: the casing assembly manipulator (90) moves the assembled casing assembly from the casing spiral rib fastening component (81) to the casing spiral rib placement table (86); S5.5: The sleeve spiral rib installation component (87) moves the sleeve assembly from the sleeve spiral rib placement table (86) to the sleeve assembly installation position (77) in the mold (14) and assembles the sleeve assembly; S5.6: The first re-inspection component (88) monitors whether the sleeve assembly is correctly installed on the sleeve assembly installation position (77) in the inner cavity of the mold (14). If it is monitored that the sleeve assembly is correctly installed on the sleeve assembly installation position (77), the mold (14) enters the truss stirrup installation and re-inspection device (6); if it is monitored that the sleeve assembly is not correctly installed on the sleeve assembly installation position (77), the first re-inspection component (88) transmits the position information of the sleeve assembly and the sleeve assembly installation position to the control center (15), and the control center (15) transmits the information to the sleeve spiral reinforcement installation component (87), and the sleeve spiral reinforcement installation component (87) corrects the position of the sleeve assembly. After the correction is completed, the mold (14) enters the truss stirrup installation and re-inspection device (6); The truss stirrup assembly method in S6 comprises the following sub-steps: S6.1: The first truss clamping claw member (62) moves the steel truss from the truss storage platform (65) to the truss receiving platform (63), and during the movement, the steel truss is flipped 180°; S6.2: The truss conveying platform (64) moves the truss receiving platform (63) equipped with the steel bar truss to one side of the input end of the truss conveyor belt (69); S6.3: The third truss clamping claw member (70) clamps the steel bar truss and places it on the truss conveyor belt (69), and the truss conveyor belt (69) conveys the steel bar truss to the truss stirrup assembly component; S6.4: The second truss clamping claw member (68) on the truss stirrup assembly component clamps the steel bar truss conveyed by the truss conveyor belt (69); S6.5: The hook clamp (71) takes the hook out of the storage assembly and conveys the hook to the truss stirrup assembly component via the hook conveyor belt (72), and the truss stirrup installation assembly (73) installs the hook on the steel bar truss; S6.6: The stirrup conveying assembly (59) takes the steel stirrups out of the steel bar funnel assembly (60) and places them on the stirrup conveying roller (58); the steel stirrups on the stirrup conveying roller (58) are conveyed to the truss stirrup assembly component via the stirrup conveyor belt (66); and the truss stirrup installation assembly (73) installs the steel stirrups on the hooks on the steel bar truss; S6.7: The second truss clamping claw member (68) on the truss stirrup assembly component transports the truss stirrup (74) assembled from the steel truss, the hook and the steel stirrup to the truss stirrup installation and re-inspection device (6); The production method of S9 comprises the following sub-steps: S9.1: conveying the semi-finished product to the storage assembly (45); S9.2: The mold clamping component (47) clamps the semi-finished product from the storage component (45) and transports it to the demoulding component (46). During the transportation process, the mold clamping component (47) turns the semi-finished product 180 degrees; S9.3: the mold clamping component (47) places the semi-finished product on the demoulding component (46), then returns to the upper side of the storage component (45) and stops conveying the next semi-finished product; S9.4: the second lifting member (52) on the demoulding assembly (46) continuously and rapidly lifts up and lowers the semi-finished product, and the first lifting member (51) prevents the mold (14) from falling but does not prevent the sleeper (12) from falling; S9.5: The detection member (53) on the detection table (50) detects whether the sleeper (12) is separated from the mold (14); if it is detected that the sleeper (12) is not separated from the mold (14), the second lifting member (52) continues to work and the mold clamping member (47) does not transport the semi-finished product; if it is detected that all the sleepers (12) are separated from the mold (14), the first lifting member (51) pushes the mold (14) upwards and keeps a certain distance from the upper side of the sleeper (12); S9.6: The sleeper transport assembly (55) enters the lower side of the sleeper (12) through the sleeper mold transport track (54), and the third lifting member (57) on the sleeper transport assembly (55) pushes the sleeper (12) upward. When the sleeper (12) is separated from the demoulding assembly (46), the sleeper transport assembly (55) transports the sleeper (12) to the sleeper detection device (11); S9.7: After the rail sleeper (12) is transported, the first lifting member (51) descends, and the mold (14) on the upper side thereof moves downward, and at the same time, the mold transport component (56) enters the lower side of the mold (14), and the third lifting member (57) on the mold transport component (56) pushes the mold (14) upward, and when the mold (14) is separated from the demoulding component (46), the mold transport component (56) transports the rail sleeper (12) to the mold cleaning device (1); S9.8: After the mold (14) is transported, the mold clamping component (47) starts to transport the semi-finished product again.

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