Production method of high-speed railway box girder prefabrication production line

Abstract

The present invention discloses a production method for a high-speed railway box girder prefabrication production line, comprising the following steps: transferring a bottom formwork from a bottom formwork insertion station to a mold closing and pouring station, installing side formwork; hoisting a reinforcement cage into the bottom formwork and side formwork of the box girder at the mold closing and pouring station; inserting an inner formwork from an inner formwork insertion and exit station into a designed position within the reinforcement cage at the mold closing and pouring station, installing end formwork; pouring concrete; demolding the side and end formworks; transferring the box girder along with the movement of the bottom formwork to a curing and pre-tensioning station for pre-tensioning strength steaming, strand threading, and pre-tensioning; demolding the inner formwork to the inner formwork insertion and exit station; transferring the box girder along with the movement of the bottom formwork to a steam curing station for initial tensioning strength steaming; and transferring the box girder along with the movement of the bottom formwork to an initial tensioning station for initial tensioning. The method of the present invention can effectively improve the production efficiency of box girders and reduce prefabrication costs.

Description

Technical Field

[0001] The invention relates to the technical field of high-speed railway box girder prefabrication, in particular to a production method of a high-speed railway box girder prefabrication production line. Background Art

[0002] With the sustained and rapid growth of the national economy, China's high-speed rail network has also embarked on a path of rapid development. During the 11th Five-Year Plan period, my country built over 5,000 kilometers of high-speed rail. According to Science and Technology Daily, by the end of 2020, my country's high-speed rail operating mileage reached 37,900 kilometers, ranking first in the world. The development of high-speed rail has significantly boosted my country's economic and social development, driven the transformation and upgrading of related industries, and fueled the rise of urban agglomerations. It has made travel more convenient and efficient for the people, enriching their lives, and demonstrating the significant potential and room for development of high-speed rail in my country.

[0003] my country's geological environment is complex, and high-speed railways need to cross rivers, hillsides, urban buildings and other areas. Therefore, bridges need to be built first in the construction of high-speed railways. In order to meet the requirements of rapid bridge construction, large-scale prefabrication yards are used, and prefabricated railway box girders have become a new construction model. Traditional high-speed railway box girders are prefabricated on a fixed platform. From placing the steel cage into the mold, closing the formwork, pouring to the completion of initial tensioning, all are completed on one platform. This traditional method has the following main problems: (1) High construction cost: To ensure the construction progress, if several box girders are to be prefabricated at the same time, on the one hand, a large number of fixed platforms and formwork systems are required. On the other hand, a large number of people are required for construction, which increases the construction cost; (2) The process is concentrated, and there is a large interference between mechanical equipment. According to the sequence of the process, it is necessary to constantly adjust the entry and exit of mechanical equipment. At the same time, mechanical equipment needs to be transferred between different workstations, which increases the difficulty of construction management; (3) Low production efficiency: At present, concrete steaming technology has become increasingly mature. The traditional fixed platform casting mode is difficult to achieve closed space steaming, low steaming efficiency, and long concrete strength time. Generally, one platform can produce a beam in 5-6 days, and the prefabrication efficiency is low; (4) High casting cost: When multiple platforms are cast at the same time, concrete needs to be transported from the mixing station to the casting site by concrete tankers, which is inefficient, fuel-intensive, and costly. Therefore, studying a production process for prefabricated box girders on an assembly line is of great significance for increasing the speed of bridge construction and reducing the cost of bridge construction. Summary of the Invention

[0004] The invention discloses a production method for a high-speed railway box girder prefabrication production line, which can effectively improve the production efficiency of the box girder and reduce the prefabrication cost.

[0005] To achieve the above object, the technical solution of the present invention is:

[0006] A production method for a high-speed railway box girder prefabrication production line, wherein the high-speed railway box girder is prefabricated in the production line, the prefabrication production line comprising a box girder production line unit, the box girder production line unit comprising a bottom mold insertion station, a mold closing and pouring station, an inner mold insertion and exit station, a curing and pre-tensioning station, a steam curing station, and an initial tensioning station, wherein an inner mold avoidance platform is provided on one side of the inner mold insertion and exit station;

[0007] The production method comprises the following steps:

[0008] S1. Installation of bottom mold and side mold: The bottom mold is transferred from the bottom mold into the mold station to the mold casting station, the side mold is installed, and the coating agent is applied;

[0009] S2. Rebar cage hoisting: Use a truss crane system to hoist the tied rebar cage into the bottom and side formwork of the box girder on the mold-closing and casting station;

[0010] S3. Inner mold mold, end mold installation: Waiting for the inner mold in the inner mold mold station by the inner mold transfer gantry into the mold to the design position of the steel cage on the mold casting station, the end mold is hoisted or transported to the mold casting station and installed to the design position by the end mold installation gantry, and the entire box girder template is assembled;

[0011] S4. Concrete pouring: concrete is poured into the box girder formwork by the distribution device, and the concrete is allowed to set;

[0012] S5. Demolding the side and end forms: Remove the beam fasteners and demold the side and end forms;

[0013] S6. Prestressing strength steam curing, strand threading, and pre-tensioning: The box girder is transferred to the pre-stressing station along with the bottom formwork. Automatic steam curing is performed in the steam curing room of the pre-stressing station. After the pre-stressing strength steam curing is completed, the prestressed strands are threaded and pre-tensioned.

[0014] S7. Inner mold demolding: The inner mold is demolded from the pre-tensioned box girder and returned to the inner mold transfer platform at the inner mold insertion and extraction station. When the next box girder needs to pass through the inner mold insertion and extraction station, the inner mold transfer platform carrying the inner mold is transferred to the inner mold avoidance station for temporary shelter.

[0015] S8 initial tension strength steam curing: after removing the inner mold box girder from the curing pre-tensioning station, along with the movement of the bottom mold is transferred to the steam curing station for initial tension strength steam curing;

[0016] S9. Initial tensioning: The box beam after the initial tensioning strength steam curing is completed is transferred to the initial tensioning station along with the movement of the bottom mold for initial tensioning. After the initial tensioning is completed, the box beam is removed from the bottom mold and entered the final tensioning storage area;

[0017] The bottom mold is transferred back to the bottom mold insertion station, and the operations of steps S1 to S9 are repeated.

[0018] Furthermore, a steel cage binding station is provided on one side of the mold closing and pouring station;

[0019] The truss crane running track of the truss crane system extends from the steel cage binding station to the mold closing and pouring station.

[0020] Furthermore, end mold avoidance platforms are provided on one side of both ends of the mold closing and casting station;

[0021] In step S3, when installing the end mold, the end mold installation stand transfers the end mold from the end mold avoidance position to the two ends of the mold closing and pouring station, and then installs the end mold to the designed position;

[0022] In step S5, after the end mold is demoulded, the end mold is transferred back to the end mold avoidance position through the end mold mounting stand.

[0023] Furthermore, a concrete mixing station is provided on the side of the mold closing and casting station away from the steel cage binding station, and a feeding track is provided between the concrete mixing station and the mold closing and casting station, and concrete is transported from the concrete mixing station to the distribution device through the feeding track.

[0024] Furthermore, the inner mold transfer platform serves as a carrier of the inner mold, and an inner mold transfer platform transverse track is arranged between the inner mold entry and exit station and the inner mold avoidance platform; inner mold transfer platform sliding beams are arranged at intervals at the bottom of the inner mold transfer platform; a winch is arranged on one side of the inner mold transfer platform transverse track to pull the inner mold transfer platform sliding beam to move on the inner mold transfer platform transverse track, thereby realizing the transfer of the inner mold between the inner mold entry and exit station and the inner mold avoidance platform.

[0025] Furthermore, the prefabrication production line further comprises a bottom mold circulation production line unit, which is arranged on one side of the box beam production line unit and extends from the initial tensioning station to the bottom mold entry station;

[0026] After the initial tensioning is completed, the bottom mold of the box beam is removed and moved horizontally from the initial tensioning station to the bottom mold circulation production line unit, and then transferred to one side of the bottom mold entering station through the bottom mold circulation production line unit.

[0027] Furthermore, the box girder production line unit further includes a bottom mold entry stand;

[0028] The bottom mold entry platform transfers the bottom mold from the tail end of the bottom mold circulation production line unit to the bottom mold entry station, and transfers the bottom mold from the bottom mold entry station to the mold closing and pouring station for entry.

[0029] Furthermore, two box girder production line units are provided, and one bottom mold circulation production line unit is provided, which is located between the two box girder production line units.

[0030] Furthermore, the bottom mold is transferred from the mold closing and pouring station to the initial tensioning station by sliding the bottom mold supported by the bottom mold transport track.

[0031] Furthermore, the bottom mold is transferred between the mold closing and pouring station and the initial tensioning station by a bottom mold pushing device;

[0032] The bottom mold pushing device includes a bottom mold transport track, a jack running track, a track clamping mechanism, a running pushing jack and a jack traveling carriage; the bottom mold transport track is provided with at least two; the jack running track is provided on one side and / or both sides of the bottom mold transport track; the track clamping mechanism can be clamped and connected to the jack running track; the rear end of the outer cylinder body of the running pushing jack is connected to the track clamping mechanism, and the front end of the piston rod is used to push the bottom mold forward; the jack traveling carriage is connected to the front part of the outer cylinder body of the running pushing jack, and can drive the running pushing jack to move along the jack running track;

[0033] A bottom mold closing plate is provided at the rear end of the bottom mold, and the front end of the traveling pushing jack forms a detachable connection with the bottom mold closing plate; bottom mold longitudinal beams are arranged at intervals under the bottom mold, and the bottom mold longitudinal beams can match and slide on the bottom mold transport track; the traveling pushing jack pushes the bottom mold closing plate, driving the bottom mold to slide on the bottom mold transport track.

[0034] The above-mentioned high-speed railway box girder assembly line prefabrication production method has the following advantages:

[0035] (1) The box beam is prefabricated in the production line. The mold casting station, curing and pre-tensioning station, steam curing station and initial tensioning station can produce different box beams at the same time, which improves work efficiency;

[0036] (2) Since multiple construction areas are designed, the concrete mixing station can be fixedly set on one side of the mold closing and pouring station for concrete pouring, which improves the automation level of box girder pouring and reduces construction costs.

[0037] (3) The pre-tensioning station and the steam curing station are used to perform pre-tensioning strength steam curing and initial tensioning strength steam curing respectively, which better realizes the steam curing in a closed space, with high steam curing efficiency and good steam curing effect.

[0038] (4) The present invention arranges each area rationally, which can reduce the interference of mechanical equipment and turnover on site, effectively reduce the difficulty of construction, and at the same time reduce the number of templates and mechanical equipment used, improve the level of automated construction of mechanized equipment, reduce the number of construction personnel, and effectively reduce the cost of prefabrication.

[0039] (5) The present invention further designs two box girder production line units and one bottom mold circulation production line unit, which can fully reduce the space occupied by the bottom mold circulation production line unit and improve space utilization. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 It is a structural diagram of an embodiment of the present invention.

[0041] Figure 2 It is a structural diagram of a bottom mold pushing device pushing a bottom mold.

[0042] Figure 3 yes Figure 2 Schematic diagram of the horizontal structure of the middle bottom mold pushing device pushing the bottom mold at the mold closing and pouring station.

[0043] Figure 4 It is a horizontal structural diagram of the bottom mold pushing device pushing the bottom mold at the inner mold entry and exit station, curing and pre-tensioning station, steam curing station, and initial tensioning station.

[0044] Figure 5 It is a structural diagram of the bottom mold pushing device.

[0045] Figure 6 It is a left-side structural schematic diagram of the slide surface layer and the slide support base plate at the mold closing and casting station.

[0046] Figure 7 yes Figure 6 Schematic diagram of the top view structure.

[0047] Figure 8 It is a left-side structural schematic diagram of the slide surface layer and slide support base plate at the inner mold entry and exit station, curing and pre-tensioning station, steam curing station, and initial tensioning station.

[0048] In the figure, the box girder production line unit 1, the bottom mold entering the mold station 101, the mold closing and pouring station 102, the inner mold entering and exiting the mold station 103, the curing and pre-tensioning station 104, the steam curing station 105, the initial tensioning station 106, the inner mold avoidance station 107, the end mold avoidance station 108, the bottom mold circulation production line unit 2, the bottom mold circulation slide 201, the bottom mold transverse track 202, the material storage station 3, the steel cage binding station 4, the truss crane system 5, the truss crane running track 501, the inner mold transfer stand 6, the end mold installation stand 7, the bottom mold entering the mold stand 8, the feeding track 9, the concrete mixing station 10, the pre-tensioning Steaming control system 11, initial tensioning steaming control system 12, track clamping mechanism 13, jack traveling vehicle 14, traveling and pushing jack 15, bottom formwork sealing plate 16, bottom formwork 17, bottom formwork longitudinal beam 18, raft foundation 19, track connection embedded parts 20, bottom formwork transport track 21, slideway surface layer 2101, slideway support bottom plate 2102, slideway second limiting structure block 2103, slideway strip foundation 22, slideway first limiting structure block 23, support pillow block 24, slideway pad 25, jack traveling track 26, slideway fixing bolt 27, limiting connection block 28, and pushing point connection structure 29. DETAILED DESCRIPTION

[0049] The present invention will be further described below with reference to specific embodiments and drawings, but the protection scope of the present invention is not limited to the following embodiments.

[0050] A production method for a high-speed railway box girder prefabrication production line, wherein the high-speed railway box girder is prefabricated in the production line, the prefabrication production line comprising a box girder production line unit 1, the box girder production line unit 1 comprising a bottom mold insertion station 101, a mold closing and pouring station 102, an inner mold insertion and exit station 103, a curing and pre-tensioning station 104, a steam curing station 105, and an initial tensioning station 106, which are sequentially arranged; an inner mold avoidance platform 107 is provided on one side of the inner mold insertion and exit station.

[0051] The production method comprises the following steps:

[0052] S1. Installing the bottom mold 17 and side molds: Move the bottom mold 17 from the bottom mold insertion station 101 to the mold closing and pouring station 102. Install the side molds, apply the coating agent, and install the necessary support plates and anti-drop embedded parts. The side molds can be automatically closed and released using electric push rods.

[0053] S2. Lifting the steel cage: Use the truss crane system 5 to lift the tied steel cage into the box beam bottom formwork 17 and side formwork on the mold closing and pouring station 102. The truss crane system can be equipped with a truss crane control system using existing technology to ensure accurate positioning of the steel cage when it is lowered.

[0054] S3. Insert the inner mold and install the end mold: The inner mold waiting at the inner mold insertion and extraction station 103 is inserted into the mold by the inner mold transfer stand 6 to the designed position in the steel cage on the mold closing and casting station 102. The end mold is hoisted or transferred to the mold closing and casting station 102 by a trolley and installed in the designed position. In addition, embedded parts such as ventilation holes, drain holes, and hoisting holes are installed to assemble the entire box girder formwork.

[0055] S4. Concrete pouring: pour concrete into the box beam formwork through the concrete placing device and wait for the concrete to finally set.

[0056] S5. Demolding of the side and end molds: Remove the beam fasteners at the mold closing and casting station 102, and demold the side and end molds.

[0057] S6. Prestressing Strength Steaming, Strand Threading, and Prestressing: As the bottom mold 17 moves, the box girder passes through the inner mold entry / exit station 103 and is transferred to the curing and prestressing station 104. Automatic steam curing is performed in the steam curing room of this curing and prestressing station 104. After prestressing strength steaming is completed, the prestressed steel strands are threaded and prestressed. During prestressing strength steaming, the steam curing room is equipped with a prestressing steaming control system 11, which automatically controls the steaming time, temperature, humidity, vacuum level, and other parameters. This is conventional technology and will not be elaborated on here.

[0058] S7. Demolding of the inner mold: The inner mold is demolded from the pre-stressed box girder and returned from the maintenance and pre-stressing station 104 to the inner mold transfer stand 6 on the inner mold entry and exit station 103; when the next box girder needs to pass through the inner mold entry and exit station 103, the inner mold transfer stand 6 carries the inner mold to the inner mold avoidance station 107 for temporary avoidance, and returns to the inner mold entry and exit station 103 after the next box girder passes, waiting for the assembly of the next box girder template.

[0059] S8. Initial Strength Steaming: After the inner mold is removed, the box girder is transferred from the curing and pre-tensioning station 104 to the steam curing station 105 along with the movement of the bottom mold 17 for initial strength steaming. Similarly, the steam curing station 105 also has a steam curing room equipped with an initial strength steaming control system 12, which can automatically control the steaming time, temperature, humidity, vacuum level, etc.

[0060] S9. Initial tensioning: The box beam after initial tensioning strength steaming is transferred to the initial tensioning station 106 along with the movement of the bottom mold 17 for initial tensioning. After the initial tensioning is completed, the production of a box beam is completed. The box beam is removed from the bottom mold 17 and enters the storage area for final tensioning.

[0061] The bottom mold is transferred back to the bottom mold insertion station 101, and the operations of steps S1 to S9 are repeated.

[0062] Furthermore, to facilitate the installation of the steel cage, a steel cage binding station 4 is provided on one side of the mold closing and pouring station 102. The steel cage binding station 4 can be equipped with 1-5 steel cage binding fixtures as needed. The gantry crane running track 501 of the gantry crane system 5 extends from the steel cage binding station 4 to the mold closing and pouring station 102. The steel cage bound at the steel cage binding station 4 can be hoisted to the mold closing and pouring station 102 by the gantry crane and lowered for installation. A material storage station 3 can also be provided on the side of the steel cage binding station 4 away from the mold closing and pouring station 102. This storage station can store materials such as steel bars and embedded parts, facilitating the production of the steel cage and the storage of embedded parts.

[0063] The transfer of the end mold can be achieved by hoisting or by transporting the end mold mounting stand 7, but hoisting requires the use of large equipment such as trusses, and the operational risk is relatively high. Furthermore, the transfer of the end mold is preferably achieved by transporting the end mold mounting stand 7, and end mold avoidance stations 108 are provided on one side of both ends of the mold closing and casting station 102; that is, each set of box girder formwork outer molds matches two sets of end molds, one set on each end. The end mold is installed by transporting the end mold mounting stand 7. Compared with hoisting, it can reduce the use of large equipment such as trusses, reduce operational risks, and reduce the difficulty of controlling the installation alignment. If a steel cage binding station 4 is provided on one side of the mold closing and casting station 102, the end mold avoidance stations 108 can be provided at both ends of the steel cage binding station 4. In step S3, when installing the end mold, the end mold installation platform 7 transfers the end mold from the end mold avoidance platform 108 to the two ends of the mold closing and pouring station 102, and then installs the end mold to the designed position. In step S5, after the end mold is demolded, the end mold is transferred back to the end mold avoidance platform 108 via the end mold installation platform 7 to avoid affecting the movement of the bottom mold 17 during the subsequent box girder station transfer. The end mold installation platform 7 can achieve lateral movement by using motor-driven running wheels. The end mold installation platform 7 can be equipped with a hydraulic pushing system to push the end mold from the end mold installation platform 7 to the designed position for installation.

[0064] Furthermore, a concrete mixing station 10 is installed on the side of the mold-closing and pouring station 102 away from the steel cage binding station 4. A feed track 9 is installed between the concrete mixing station 10 and the mold-closing and pouring station 102. Concrete mixed by the concrete mixing station 10 is discharged from the concrete mixing station outlet into the feed hopper, and then transported to the mold-closing and pouring station 102 via the feed track 9. The concrete is poured into the box girder formwork by the distribution device. The concrete mixing station 10 is fixedly installed on the side of the mold-closing and pouring station 102 for concrete pouring, which improves the automation level of box girder pouring while reducing construction costs.

[0065] Furthermore, an inner mold transfer platform transverse track is provided between the inner mold entry and exit station 103 and the inner mold avoidance station 107; an inner mold transfer platform sliding beam is provided at intervals at the bottom of the inner mold transfer platform 6; a winch is provided on one side of the inner mold transfer platform transverse track to pull the inner mold transfer platform sliding beam to move on the inner mold transfer platform transverse track, thereby transferring the inner mold between the inner mold entry and exit station 103 and the inner mold avoidance station 107. The inner mold transfer platform 6 has a power system, which can use a motor to drive a gear, and the inner mold is provided with a prefabricated meshing rack. The motor drives the gear, and the gear drives the rack to move, so that the inner mold is moved from the inner mold transfer platform 6 into the steel cage on the mold closing and pouring station 102.

[0066] Furthermore, the prefabrication production line also includes a bottom mold circulation production line unit 2, which is arranged on one side of the box girder production line unit 1, extending from the initial tensioning station 106 to the bottom mold entry station 101; after the initial tensioning is completed, the bottom mold 17 removed from the box girder is moved horizontally from the initial tensioning station 106 to the bottom mold circulation production line unit 2, and transferred to one side of the bottom mold entry station 101 through the bottom mold circulation production line unit 2.

[0067] Furthermore, the box girder production line unit also includes a bottom mold entry gantry; the bottom mold 17 enters the mold closing and pouring station 102 from the bottom mold entry station 101 and is entered into the mold using the bottom mold entry gantry 8. In addition, the bottom mold entry gantry 8 also transfers the bottom mold 17 from the tail end of the bottom mold circulation production line unit 2 to the bottom mold entry station 101. The bottom mold entry gantry 8 can be moved by a motor-driven walking wheel. For the bottom mold to enter the bottom mold entry gantry 8 or leave the bottom mold entry gantry 8, a gear and rack moving method can be used. For example, a gear with a motor is provided on the bottom mold, and a rack meshing with it is provided on the top surface of the bottom mold entry gantry 8. The bottom mold 17 is transferred from the tail end of the bottom mold circulation production line unit 2 to the bottom mold entry gantry 8, and from the bottom mold entry gantry 8 to the mold closing and pouring station 102, both are moved by a motor-driven gear and a gear running on the rack. The transfer of the bottom mold 17 from the mold closing and pouring station 102 to the initial tensioning station 106 is achieved by the bottom mold transport track carrying the bottom mold 17. The movement of the bottom mold 17 in the bottom mold circulation production line unit 2 is achieved by the bottom mold circulation slide 201 carrying the bottom mold 17.

[0068] Furthermore, the bottom mold 17 is transferred between the mold closing and casting station 102 and the initial tensioning station 106 by a bottom mold pushing device; Figure 5As shown, the bottom mold pushing device includes a bottom mold transport track 21, a jack running track 26, a track clamping mechanism 13, a running pushing jack 15 and a jack traveling vehicle 14; at least two bottom mold transport tracks 21 are provided, and this embodiment uses three bottom mold transport tracks 21 as an example. The bottom mold transport track 21 can carry the bottom mold 17 and slide on it; the jack running track 26 is provided on one side and / or both sides of the bottom mold transport track 21, and the number is the same as that of the running pushing jack 15. In order to maintain the pushing balance, the jack running track 26 of this embodiment is provided as follows: the jack running tracks 26 are symmetrically provided on both sides of the bottom mold transport track 21 in the middle. The top running track 26 is provided with a jack running track 26 on the inner side of the bottom mold transport track 21 on both sides, and is symmetrically arranged with the center line of the bottom mold transport track 21 in the middle as the symmetry axis; the track clamping mechanism 13 can be clamped and connected to the jack running track 26, that is, when the running jack 15 is pushing, the jack running track 26 is clamped to form a pushing reaction force to ensure that the running jack 15 does not move backward. When the position of the running jack 15 needs to be adjusted, the jack running track 26 is loosened to complete the adjustment of the position of the running jack 15; the rear end of the outer cylinder of the running jack 15 is connected to the track clamping mechanism 13 Then, the front end of the piston rod is used to push the bottom mold 17 forward to adjust the bottom mold 17 to a suitable working position. A hydraulic jack is used. The number of hydraulic jacks should be considered to make the two sides of the bottom mold 17 pushed evenly, and the positions are symmetrical relative to the center line of the bottom mold 17; the jack traveling carriage 14 is connected to the front part of the outer cylinder body of the traveling jack 15, and can drive the traveling jack 15 to move along the jack traveling track 26. The jack traveling carriage 14 has a rolling structure. When driven by external force or by itself, it is self-driven, such as the motor drives the roller to rotate, which can help the traveling jack 15 to adjust its position; A bottom mold closing plate 16 is provided at the rear end of the bottom mold 17, and the front end of the traveling pushing jack 15 is detachably connected to the bottom mold closing plate 16. The bottom mold closing plate 16 is connected to the rear end of the bottom mold 17 and extends downward to ensure that the traveling pushing jack 15 is horizontally set to push the bottom mold closing plate 16. The bottom mold closing plate 16 needs to have space to accommodate the jack running track 26 and the bottom mold transport track 21 to ensure smooth pushing; bottom mold longitudinal beams 18 are arranged at intervals under the bottom mold 17, and the bottom mold longitudinal beams 18 can match and slide on the bottom mold transport track 21; the traveling pushing jack 15 pushes the bottom mold closing plate 16, driving the bottom mold 17 to slide on the bottom mold transport track 21.

[0069] For the setting of the bottom mold transport track 21, it is necessary to consider the track support foundation and the track itself. For the track itself, combined with Figure 2 、 Figure 3 、 Figure 6 and Figure 7As shown, in this embodiment, the bottom mold transport track 21 at the mold closing and casting station includes a slide surface layer 2101, a slide support base plate 2102, and a slide second limiting structure block 2103. The slide surface layer 2101 is arranged on the upper middle part of the slide support base plate 2102, that is, the surface layer of the bottom mold transport track, and is made of polytetrafluoroethylene synthetic material. It contacts the bottom mold longitudinal beam 18 and has a width smaller than the slide support base plate 2102 and matches the width of the bottom mold longitudinal beam 18. The slide support base plate 2102 is made of steel material to provide rigid support for the slide surface layer 2101. 1. The second limiting structure blocks 2103 of the slide are set on both sides. The second limiting structure blocks 2103 of the slide are welded to the slide support base plate 2102 to prevent the slide surface layer 2101 from shifting left and right. The second limiting structure blocks 2103 of the slide are slightly smaller than or the same height as the slide surface layer 2101. In addition, since the mold closing and pouring station 102 needs to carry out the template assembly process, in order to prevent the overall rotation and offset during the box girder pouring construction, the first limiting structure blocks 23 of the slide are welded on the second limiting structure blocks 2103 of the slide, so that the first limiting structure blocks 23 of the slide are higher than the upper surface of the slide surface layer 2101. At the inner mold entry and exit station 103, the curing and pre-tensioning station 104, the steam curing station 105, and the initial tensioning station 106, due to the fewer operating procedures and in order not to affect the lateral movement operations related to the box girder, Figure 4 and 8 As shown, the bottom mold transport track 21 is not welded with the first limiting structure block 23 of the slideway.

[0070] This embodiment provides a track foundation that is better resistant to disturbances, combined with Figure 2-4As shown, first cast the raft foundation 19. According to this embodiment, three bottom mold transport tracks 21 need to be set. Three parallel slide strip foundations 22 are cast on the raft foundation 19. When casting the slide strip foundation 22, the track connection embedded parts 20 for fixing the bottom mold transport track 21 are pre-embedded. The lower end of the track connection embedded parts 20 extends into the slide strip foundation 22, and the upper part is exposed outside the slide strip foundation 22. The top surface is provided with an embedded part connecting plate, and then the exposed track connection embedded parts are pre-embedded. A support pillow block 24 is cast at the position of the embedded part 20, and the support pillow block 24 is exposed on the surface of the embedded part connecting plate. The support pillow block 24 is the same as the embedded part and is arranged at intervals along the length direction of the slide strip foundation 22. The support pillow block 24 is reserved with a track placement groove and a push jack placement groove. The push jack placement groove is placed with a jack running track 26 so that the jack running track 26 does not expose the upper surface of the support pillow block 24, which is convenient for the subsequent lateral movement operation of the inner mold transfer stand 6 and the bottom mold. A slide pad 25 is provided in the track placement groove. The slide pad 25 can be made of a material with a bottom layer of EPDM rubber material and a surface layer of ductile iron to play a shock-absorbing, buffering and impact-resistant role between the concrete structure and the bottom form transport track 21. A long strip of bottom form transport track 21 is placed on the slide pad 25. Limiting connection blocks 28 are arranged at intervals on both sides of the slide support base plate 2102. The limiting connection blocks 28 are right-angled, one side is pressed on one side of the slide support base plate 2102 to fix the bottom form transport track 21, and the other side is stuck on the outer side surface of the slide support base plate 2102. The limiting connection blocks 28 and the slide pads 25 are both provided with bolt holes, which are through holes. The embedded part connecting plate is provided with bolt holes, which are blind holes. The slide fixing bolts 27 are screwed into the bolt holes of the limiting connection blocks 28, the slide pads 25 and the embedded part connecting plates to complete the fixation of the bottom form transport track 21.

[0071] To prepare for the push of the bottom mold 17, the track clamping mechanism 13 is installed at the position corresponding to the jack running track 26. Then, the running push jack 15 and jack carriage 14 are installed. A longitudinal beam is secured beneath the bottom mold 17, its position aligning with the bottom mold transport track 21. The bottom mold cover plate 16 is secured to the rear end of the bottom mold 17, and the bottom mold 17 is placed on the bottom mold transport track 21. When the bottom mold 17 needs to be moved to another station, the bottom mold cover plate 16 is connected to the front end of the piston rod of the running push jack 15 via a push point connection structure 29, which can be a flange structure. The track clamping mechanism 13 is started, clamping the jack running track 26, forming a pushing reaction force to ensure that the running pushing jack 15 does not move backward, the piston rod of the running pushing jack 15 extends forward, and the pushing bottom mold 17 carries the box beam along the bottom mold transport track 21. When the running pushing jack 15 completes a pushing stroke, the track clamping mechanism 13 is closed, the track clamping mechanism 13 releases the jack running track 26, and the piston rod of the running pushing jack 15 retracts, driving the track clamping mechanism 13 to move forward. After the piston rod of the running pushing jack 15 returns, the track clamping mechanism is started. Structure 13, start the next stroke pushing operation, and repeat this cycle until the bottom mold 17 carrying the box girder completes a station transfer; after completing the station transfer, the piston rod of the traveling pushing jack 15 is separated from the bottom mold 17, and the traveling pushing jack 15 needs to be transferred from the initial tensioning station 106 to the mold casting station 102. At this time, the jack traveling carriage 14 is started to drive the traveling pushing jack 15 to walk on the jack traveling track 26 to the corresponding mold casting station 102, the jack traveling carriage 14 stops moving, and the traveling pushing jack 15 starts a new station transfer operation.

[0072] Furthermore, two box girder production line units 1 are provided, and one bottom mold circulation production line unit 2 is provided, which is located between the two box girder production line units 1. This can more reasonably and fully utilize the space and reduce the space occupied by the bottom mold circulation production line unit 2.

Claims

1. A production method for a high-speed railway box girder prefabrication production line, characterized by: High-speed railway box girders are prefabricated in a production line comprising a box girder production line unit, which includes a bottom mold entry station, a mold closing and pouring station, an inner mold entry and exit station, a curing and pre-tensioning station, a steam curing station, and an initial tensioning station. An inner mold avoidance station is provided on one side of the inner mold entry and exit station; end mold avoidance stations are provided on one side of both ends of the mold closing and pouring station. The production method comprises the following steps: S1. Installation of bottom mold and side mold: The bottom mold is transferred from the bottom mold into the mold station to the mold casting station, the side mold is installed, and the coating agent is applied; S2. Rebar cage hoisting: Use a truss crane system to hoist the tied rebar cage into the bottom and side formwork of the box girder on the mold-closing and casting station; S3. Inner mold mold, end mold installation: Waiting for the inner mold in the inner mold mold station by the inner mold transfer gantry into the mold to the design position of the steel cage on the mold casting station, the end mold is hoisted or transported to the mold casting station and installed to the design position by the end mold installation gantry, and the entire box girder template is assembled; S4. Concrete pouring: concrete is poured into the box girder formwork by the distribution device, and the concrete is allowed to set; S5. Demolding the side and end forms: Remove the beam fasteners and demold the side and end forms; S6. Prestressing strength steam curing, strand threading, and pre-tensioning: The box girder is transferred to the pre-stressing station along with the bottom formwork. Automatic steam curing is performed in the steam curing room of the pre-stressing station. After the pre-stressing strength steam curing is completed, the prestressed strands are threaded and pre-tensioned. S7. Inner mold demolding: The inner mold is demolded from the pre-tensioned box girder and returned to the inner mold transfer platform at the inner mold insertion and extraction station. When the next box girder needs to pass through the inner mold insertion and extraction station, the inner mold transfer platform carrying the inner mold is transferred to the inner mold avoidance station for temporary shelter. S8 initial tension strength steam curing: after removing the inner mold box girder from the curing pre-tensioning station, along with the movement of the bottom mold is transferred to the steam curing station for initial tension strength steam curing; S9. Initial tensioning: The box beam after the initial tensioning strength steam curing is completed is transferred to the initial tensioning station along with the movement of the bottom mold for initial tensioning. After the initial tensioning is completed, the box beam is removed from the bottom mold and entered the final tensioning storage area; The bottom mold is transferred back to the bottom mold insertion station, and the operations of steps S1 to S9 are repeated repeatedly; Wherein: in step S3, when installing the end mold, the end mold installation stand transfers the end mold from the end mold avoidance position to the two ends of the mold closing and pouring station, and then installs the end mold to the designed position; In step S5, after the end mold is demoulded, the end mold is transferred back to the end mold avoidance position through the end mold mounting stand.

2. The production method of the high-speed railway box girder prefabrication production line according to claim 1, characterized in that: A steel cage binding station is provided on one side of the mold closing and pouring station; The truss crane running track of the truss crane system extends from the steel cage binding station to the mold closing and pouring station.

3. The production method of the high-speed railway box girder prefabrication production line according to claim 2, characterized in that: A concrete mixing station is provided on the side of the mold closing and pouring station away from the steel cage binding station. A feeding track is provided between the concrete mixing station and the mold closing and pouring station. Concrete is transported from the concrete mixing station to the distribution device through the feeding track.

4. The prefabrication production method for a high-speed railway box girder prefabrication production line according to claim 1, characterized in that: An inner mold transfer platform transverse track is arranged between the inner mold entry and exit station and the inner mold avoidance platform; an inner mold transfer platform sliding beam is arranged at intervals at the bottom of the inner mold transfer platform; a winch is arranged on one side of the inner mold transfer platform transverse track, which pulls the inner mold transfer platform sliding beam to move on the inner mold transfer platform transverse track, thereby realizing the transfer of the inner mold between the inner mold entry and exit station and the inner mold avoidance platform.

5. The production method of the high-speed railway box girder prefabrication production line according to any one of claims 1 to 4, characterized in that: The prefabrication production line further comprises a bottom mold circulation production line unit, which is arranged on one side of the box beam production line unit and extends from the initial tensioning station to the bottom mold entering station; After the initial tensioning is completed, the bottom mold of the box beam is removed and moved horizontally from the initial tensioning station to the bottom mold circulation production line unit, and then transferred to one side of the bottom mold entering station through the bottom mold circulation production line unit.

6. The production method of the high-speed railway box girder prefabrication production line according to claim 5, characterized in that: The box beam production line unit further includes a bottom mold entry stand; The bottom mold entry platform transfers the bottom mold from the tail end of the bottom mold circulation production line unit to the bottom mold entry station, and transfers the bottom mold from the bottom mold entry station to the mold closing and pouring station for entry.

7. The production method of the high-speed railway box girder prefabrication production line according to claim 6, characterized in that: There are two box girder production line units, and one bottom mold circulation production line unit is provided, which is located between the two box girder production line units.

8. The production method of the high-speed railway box girder prefabrication production line according to any one of claims 1 to 4, characterized in that: The bottom mold is transferred from the mold closing and pouring station to the initial tensioning station by sliding the bottom mold supported by the bottom mold transport track.

9. The production method of the high-speed railway box girder prefabrication production line according to claim 8, characterized in that: The bottom mold is transferred between the mold closing and pouring station and the initial tensioning station by a bottom mold pushing device; The bottom mold pushing device includes a bottom mold transport track, a jack running track, a track clamping mechanism, a running pushing jack and a jack traveling carriage; the bottom mold transport track is provided with at least two; the jack running track is provided on one side and / or both sides of the bottom mold transport track; the track clamping mechanism can be clamped and connected to the jack running track; the rear end of the outer cylinder body of the running pushing jack is connected to the track clamping mechanism, and the front end of the piston rod is used to push the bottom mold forward; the jack traveling carriage is connected to the front part of the outer cylinder body of the running pushing jack, and can drive the running pushing jack to move along the jack running track; A bottom mold closing plate is provided at the rear end of the bottom mold, and the front end of the traveling pushing jack forms a detachable connection with the bottom mold closing plate; bottom mold longitudinal beams are arranged at intervals under the bottom mold, and the bottom mold longitudinal beams can match and slide on the bottom mold transport track; the traveling pushing jack pushes the bottom mold closing plate, driving the bottom mold to slide on the bottom mold transport track.

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