Concrete shock excitation forming equipment and process thereof

Abstract

The invention relates to concrete shock excitation forming equipment and a process thereof, and belongs to the field of industrial automation. The concrete shock excitation forming equipment comprises a control system, a shock excitation system and a forming mold, the shock excitation system is an electro-hydraulic shock excitation system controlled by a 2D shock excitation valve 1 and comprises a hydraulic source and an actuator connected with the 2D shock excitation valve, and two oil ports of the 2D shock excitation valve are communicated with high-pressure oil and return oil respectively. According to the corresponding shock excitation forming process, the frequency can be adjusted to be 50-200 Hz, the amplitude can be changed within the range of 5-500 mm, the amplitude change direction is opposite to the frequency change direction, and the shock excitation forming time is 60-150 s. High-thrust high-frequency vibration can be achieved through electro-hydraulic excitation, and the defects that mechanical vibration is low in frequency and fixed in amplitude are overcome. And the actuator can be arbitrarily arranged to vibrate in the horizontal direction or the vertical direction. The gravity load of the materials can be prevented from being borne through horizontal vibration, and the energy-saving effect is achieved. The forming mold can be popularized and applied to all concrete shock excitation forming processes, and the production efficiency can be greatly improved through the large forming mold.

Description

Technical Field

[0001] The invention relates to a concrete component production device and a process thereof, in particular to a special equipment for producing a train sleeper and a molding process, and belongs to the field of industrial automation. Background Art

[0002] my country's own sleeper production line started in the 1990s. Although it started late in my country, it has developed rapidly. Now, after a long period of industrial production, we have accumulated a lot of experience, and some excellent production technologies that are ahead of the world have been developed. my country has gradually become a leader in this field. However, in the construction of specific sleeper production lines, there are still some deficiencies, such as the lack of intelligent and automated production, and the lack of experience in equipment maintenance and management. The production efficiency needs to be improved and the noise in the production environment is too high, which threatens the physical and mental health of workers, especially the concrete excitation production line that is mainly responsible for the vibration molding of sleepers. This is mainly because the vibration is mostly mechanical vibration formed by eccentric blocks. Although there is a large vibration force and a large amplitude, the vibration direction is that the huge mold filled with concrete vibrates up and down on the platform. Because the exciting force is a sinusoidal change of time, when the absolute value of the upward acceleration is higher than the acceleration of gravity and the downward acceleration value is greater than one g, the molding mold will leave the platform twice, that is, the impact frequency is twice the vibration frequency. The general frequency of mechanical vibration is 40-50Hz, and the corresponding impact frequency is 80-100Hz. Although the frequency is objectively increased and the vibration effect is enhanced, the high-energy collision between the steel mold and the steel platform has high noise energy and high noise hazards. In order to reduce noise, the mold must be reliably "tied" to the platform to avoid the above-mentioned collision. 202421119580.1 The same is true for the excitation principle of a material compact and uniform vibration platform. The current electro-hydraulic vibration machine is mainly composed of hydraulic oil source, electro-hydraulic servo valve, hydraulic actuator, frame and computer control system. The high-frequency servo valve controls the hydraulic power source to enter and exit the two chambers of the hydraulic cylinder or hydraulic motor, driving the piston to output the hydraulic pressure. Due to the inherent characteristics of the servo valve, it is difficult to meet the requirements of high frequency and wide amplitude at the same time. The most critical thing is that the sleeper production line can only adopt multi-platform vibration, especially mechanical vibration, because of the huge load and large size of high-power motors. It is difficult to accurately adjust the force output phase of each platform, resulting in an embarrassing situation of three monks having no water to drink. Therefore, it is necessary to develop a concrete vibration forming equipment and process with high degree of automation, good vibration effect and excellent human-machine environment. Summary of the invention

[0003] The purpose of the present invention is to provide a concrete component production equipment and process thereof, which can overcome the above-mentioned technical problems: the present invention discloses a concrete vibration molding equipment, including a control system, a vibration system and a molding mold. The vibration system is an electro-hydraulic vibration system controlled by a 2D vibration valve, including an actuator directly connected to a hydraulic source and a 2D vibration valve, and the two oil ports of the 2D vibration valve are respectively connected to high-pressure oil and return oil. The 2D vibration valve used in the present invention is a new type of high-efficiency hydraulic component invented by Professor Ruan Jian of Zhejiang University of Technology. Driving the valve can realize fluid flow reversal. When the valve core rotates at high speed, the fluid flow switches at high frequency in the inlet and outlet oil chambers of the actuator to realize actuator vibration. The 2D vibration valve has adjustable frequency and amplitude, which overcomes the shortcomings of low mechanical vibration frequency and fixed amplitude. The high energy density of hydraulic oil can achieve high-thrust and high-frequency vibration. For the production line of sleepers for forming concrete components, it does not need to have a large amplitude. The key indicators of high thrust and high frequency are not required, and the actuator can be arranged to vibrate horizontally or vertically at will. If it is arranged to vibrate horizontally, it can avoid bearing the gravity load of the material and achieve energy saving. Compared with mechanical transmission belts, the advantage of hydraulic transmission is that it is easy to control, flexible in installation and arrangement, and greatly reduces mechanical vibration.

[0004] Preferably, a concrete vibration forming device comprises a control system, a vibration system and a forming mold, wherein the vibration system is an electro-hydraulic vibration system controlled by a 2D vibration valve, comprising a hydraulic source and a plurality of actuators connected to a 2D vibration valve through a sequential control circuit or a synchronous circuit, and the two oil ports of the 2D vibration valve are respectively connected to high-pressure oil and return oil.

[0005] This set of equipment can use the sequential control loop to realize the horizontal vibration and vertical vibration in sequence. The synchronous loop can ensure that the parallel multiple vertical vibration actuators vibrate at the same frequency, amplitude and phase, avoiding the asynchronous vibration of the upper and lower parts, which will cause greater noise and energy cancellation.

[0006] As a preferred embodiment, in a concrete vibration forming device, one end of the forming mold is connected to the protruding end of the actuator by an automatic train coupler. In order to conveniently move the forming mold to the next station after horizontal vibration and ensure the production line beat, one end of the forming mold needs to be rhythmically coupled and coupled with the actuator. The automatic train coupler can achieve reliable connection under heavy loads and can be automatically disconnected.

[0007] As a preferred embodiment, a concrete vibration forming device, the forming mold is equipped with wheels and placed on the rails. In order to support the forming mold filled with materials and not to damage the road surface, the train transportation method is directly referred to, and the products of the sleepers can be produced and sold by themselves. The most important thing is to change the sliding friction into rolling friction. When the forming mold vibrates horizontally forward and backward along the forward direction of the forming mold, the knocking noise between the forming mold and the platform can be completely avoided.

[0008] As a preferred embodiment, a concrete vibration forming device is provided, wherein the forming mold is provided with a slide rail, and is placed on a track groove covered with cylindrical rollers. The cooperation between the slide rail and the track groove increases the contact area, and the slide rail can run silently on the cylindrical roller. When the forming mold vibrates horizontally forward and backward along the forward direction of the forming mold, the knocking noise between the forming mold and the platform can be completely avoided. In addition, the center of gravity of this solution is low, and it is safer.

[0009] Preferably, a concrete vibration forming device is provided, in which one actuator can be arranged in parallel along the forward direction of the forming mold, and the other actuators are arranged in a vertical direction. The actuators are connected to the platform and the displacement, frequency, and amplitude vibration parameter settings must be kept consistent. This arrangement can achieve horizontal and vertical bidirectional vibration, further enhance the vibration effect, expel the air in the concrete, and ensure that the material is evenly distributed and dense. And the actuator in the vertical direction can vibrate with the same frequency, amplitude, and phase under the synchronous control loop, avoiding greater noise and energy cancellation caused by asynchronous up and down vibration. The horizontal front and back vibration and the vertical up and down vibration can be changed in order according to the required sequence. Moreover, the frequency and amplitude excitation force in both directions can be adjusted independently, reflecting the advantages of the hydraulic system.

[0010] Preferably, in a concrete vibration forming equipment, the hydraulic source is a high-pressure and high-power plunger pump. Because in the concrete vibration forming process, high-thrust and high-frequency vibration is required, in order to achieve the process purpose, the hydraulic source needs to be a high-pressure and high-power plunger pump, such as an aviation plunger pump, with a pressure level of up to 53MPa and a large flow rate, which ensures the vibration force at high frequency. In mechanical vibration, the sinusoidal change of the vibration force caused by the vibration of the eccentric block, and the production stoppage caused by the eccentricity, which affects the improvement of productivity, are avoided.

[0011] As a preferred embodiment, in a concrete excitation forming device, the actuator is a piston cylinder, and a three-position five-way servo valve of a sliding valve type can be connected in parallel. The initial vibration position of the piston in the piston cylinder can be automatically adjusted by the parallel sliding valve type three-position five-way servo valve, so as to ensure that several parallel actuators vibrate in the same phase at the same frequency, force and amplitude, maintain synchronization, avoid energy consumption of different actuators due to vertical vibration, and reduce noise.

[0012] A vibration forming process for concrete, which can adjust the frequency to 50-200Hz by adjusting the valve core speed of a 2D vibration valve, and can steplessly adjust the axial displacement of the valve core to achieve an amplitude change in the range of 5-500mm, with the amplitude change direction being opposite to the frequency change, and the vibration forming time being 60-150s. The climate in the north and south of my country is complex and diverse, and the temperature and humidity in different seasons are significantly different. The advantage of using the concrete vibration forming equipment disclosed in the present invention lies in the adjustable frequency, amplitude, vibration force and other parameters, combined with the time allocation of horizontal front and rear vibration and vertical up and down vibration, to better adapt to the difference in concrete hardening speed caused by weather changes. For example, in winter, the vibration time can be reduced, the amplitude can be reduced, the frequency can be increased, and the vibration force can be reduced to achieve the effect of noise reduction and energy saving.

[0013] As a concrete excitation molding process, the frequency, amplitude, and vibration time of the forward and backward reciprocating vibration along the forward direction of the molding die and the up and down reciprocating vibration of the platform can be adjusted independently, and the order of vibration can be changed. For the two-axis vibration of the multi-actuator vibration, it is necessary to adjust the process parameters according to the different load sizes in different directions and the distribution characteristics of the materials. The vibration frequency in the forward direction of the molding die can be lower than that in the longitudinal direction, with a larger amplitude, smaller vibration force, and shorter vibration time. Because the horizontal direction is only affected by rolling friction, while the vertical direction is affected by the weight of the platform and the weight of the fully loaded molding die.

[0014] Therefore, the present invention has the characteristics of reasonable structure, advanced vibration method and superior production technology. It is particularly suitable for concrete components, such as rail sleeper vibration forming process, and can effectively overcome the problems of low frequency and small amplitude of mechanical vibration in heavy load excitation and the shortcomings of fixed frequency and amplitude of mechanical vibration and high noise. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 1 is a schematic diagram of the structure of Embodiment 1 of the present invention (vibration to the left); Figure 2 yes Figure 1 Hydraulic schematic diagram; Figure 3 This is a schematic diagram of the structure of Embodiment 1 of the present invention (vibration to the right) Figure 4 yes Figure 3 Hydraulic schematic diagram; Figure 5 It is a structural schematic diagram of the forming mold 3; Figure 6 yes Figure 5 AA section diagram; Figure 7 is with Figure 5 A schematic diagram of the structure of the steel rail 5 matched with the forming die; Figure 8 yes Figure 7 sectional view of Fig. 9 is another structural diagram of the forming die 3; Fig.10 yes Fig. 9 AA section diagram; Fig.11 is with Fig. 9 A schematic diagram of the structure of the track groove 6 that matches the molding die 3; Fig.12 yes Fig.11 sectional view of Fig.13 1 is a hydraulic principle diagram of Embodiment 2 of the present invention (upward vibration); Fig.14 1 is a hydraulic principle diagram of Embodiment 2 of the present invention (downward vibration); Fig.15 is a hydraulic principle diagram of embodiment 3 of the present invention (multi-actuator sequential circuit); Fig.16 is a hydraulic principle diagram of embodiment 4 of the present invention (multi-actuator synchronization circuit); Fig.17 It is a working principle diagram of a mechanical centrifugal vibrator in the prior art.

[0016] In the figure: 1. 2D excitation valve; 1a. Valve type; 1b. Valve sleeve; 1c. Window; 2. Actuator; 3. Forming die; 3a. Wheel; 3b. Slide rail; 4. Automatic coupler for train; 5. Rail; 6. Track groove; 6a. Cylindrical roller; 7. Sliding valve type three-position five-way servo valve; 8. Platform; 9. Eccentric block. DETAILED DESCRIPTION

[0017] The technical solution of the present invention is further specifically described below through embodiments and in conjunction with the accompanying drawings.

[0018] Embodiment 1: Figures 1 to 8 The scheme published, combined with the existing technology, Fig.17 The working principle diagram of the mechanical centrifugal vibrator is explained in detail. A concrete vibration molding equipment, including a control system, a vibration system and a molding mold 3. The vibration system is an electro-hydraulic vibration system controlled by a 2D vibration valve 1, including a hydraulic source directly connected to a 2D vibration valve 1 and an actuator 2 arranged horizontally along the forward direction of the mold, specifically a certain type of piston cylinder. The two oil ports of the 2D vibration valve 1 are connected to the high-pressure oil and the return oil respectively. One end of the molding mold 3 is connected to the protruding end of the actuator 2 by an automatic coupler 4 for a train. The hydraulic source used is an imported aviation plunger pump with a pressure rating of 35MPa and a maximum flow rate of 225 liters / min. The molding mold 3 is equipped with wheels 3a and is placed on the rails 5, such as Figure 5As shown. In order to support the forming mold 3 filled with materials and not to damage the road surface, the train transportation method is directly referred to, and the products produced by the sleepers can be produced and sold by themselves. The most important thing is to change the sliding friction into rolling friction. When the forming mold 3 vibrates horizontally forward and backward along the forward direction, the knocking noise between the forming mold and the platform 8 can be completely avoided.

[0019] In order to conveniently move the molding die to the next workstation after horizontal vibration and ensure the production line rhythm, it is necessary to rhythmically clutch one end of the molding die 3 with the actuator 2. The automatic train coupler 4, such as the Zhan coupler, can achieve reliable connection under heavy loads and can automatically disengage. The 2D excitation valve 1 adopted in the present invention is a new type of high-efficiency hydraulic component invented by Professor Ruan Jian of Zhejiang University of Technology. Driving the valve can realize high-frequency reversing of the liquid flow. When the valve core 1a rotates at high speed, the window 1c can be periodically closed with the fixed valve sleeve 1b, and the high-pressure liquid flow switches the direction of the two oil chambers of the actuator 2 at a high frequency to realize the excitation of the actuator 2. The axial displacement of the driving valve core 1a can also change the flow rate and flow rate from the axial switch window 1c. In short, the 2D excitation valve 1 has adjustable frequency and amplitude, which overcomes the Fig.17 The mechanical vibration in the eccentric block 9 rotates at a high speed of 3000 rpm, but the frequency is only 50 Hz, and the amplitude is fixed. Hydraulic transmission has a high energy density and can achieve high-thrust and high-frequency vibration. For the sleeper production line of concrete component molding, it is not actually necessary to have a large amplitude. The key indicator is high thrust and high frequency. The actuator 2 can be arranged to vibrate horizontally to avoid bearing the gravity load of the material and achieve energy saving. The advantage of hydraulic transmission over mechanical transmission belt is that it is easy to control, flexible in installation and layout, and greatly reduces mechanical noise.

[0020] The concrete forming process of this embodiment is to adjust the valve core speed of the 2D excitation valve 1 to adjust the frequency to 50Hz, and the axial displacement of the valve core can be infinitely adjusted to achieve an amplitude of 500mm. The amplitude change direction is opposite to the frequency change, and the excitation forming time is 60-150s. Because it is arranged in the horizontal direction, the pressure of the aviation plunger pump can be reduced, the flow rate can be increased, and the mold 3 can be vibrated greatly front and back to improve the molding quality of the concrete. In addition, considering the complex and diverse climates in the north and south of my country, the weather temperature and humidity in different seasons are significantly different. The advantage of using the concrete excitation forming equipment disclosed in the present invention is that the adjustable frequency amplitude excitation force and other parameters, combined with horizontal front and rear vibration, better adapt to the difference in concrete hardening speed caused by weather changes. For example, in winter, the vibration time can be reduced to 60s, the amplitude can be reduced by 300 mm, and the frequency can be increased to 100 Hz. By adjusting the pressure of the aviation plunger pump to reduce the excitation force, the effect of noise reduction and energy saving can be achieved. The biggest advantage is that the length of the molding mold 3 is consistent with the train car, and the mold can simultaneously mold multiple concrete components at a time, which greatly improves production efficiency.

[0021] Example 2: Figures 9 to 14 The disclosed concrete vibration forming equipment adopts the hydraulic vibration system of the same principle as that of the first embodiment, including a vertically arranged actuator 2, specifically a piston cylinder of a certain type, directly connected to a hydraulic source and a 2D vibration valve 1. The two oil ports of the 2D vibration valve 1 are connected to the high-pressure oil and the return oil respectively. The piston rod of the actuator 2 is connected to the platform 8, and the platform 8 can be provided with the following Fig. 9 The bottom of the molding die 3 shown is provided with a parallel slide rail 3b, which is placed on the track groove covered with cylindrical rollers 6a. The cooperation of the slide rail 3b and the track groove increases the contact area, and the slide rail can run silently on the cylindrical roller. When the molding die 3 vibrates horizontally in the forward direction, the knocking noise between the molding die and the platform 8 can be completely avoided. And the center of gravity of this scheme is low and safer. Because the vertical load is much greater than the horizontal rolling friction of Example 1, the maximum pressure of the matching aviation plunger pump should be 53MPa and the corresponding flow rate is also as small as 120 liters / minute, but the frequency can be increased to 200 Hz by adjusting the speed of the 2D excitation valve 1, and the axial adjustment is to the maximum window 1c to obtain a large excitation force and a large amplitude. However, because of the high frequency, the maximum amplitude is also much lower than that of Example 1, only 5 mm. At the same time, the high frequency can greatly reduce the vibration time to 60s. Of course, depending on the actual production needs, the vibration time can also be appropriately extended, but experiments have shown that under high-frequency vibration, too long up and down vibration is harmful. Because the aggregate in the concrete will sink, while the mortar will float, it wastes energy and increases noise.

[0022] Example 3: Fig.15 The disclosed concrete vibration forming equipment is a dual-actuator sequential circuit, that is, the same set of hydraulic sources and the same 2D vibration valve 1, in which one actuator 2 can be arranged in parallel along the forward direction of the forming mold, and the other actuator 2 is arranged in a vertical direction, and the piston rod of the actuator 2 is connected to the platform 8. The maximum pressure of the matching aviation plunger pump should be 53MPa. This arrangement can achieve horizontal and vertical bidirectional vibration, and has the advantages of embodiment 1 and embodiment 2. It can further enhance the vibration effect, expel the air in the concrete, and ensure that the material is evenly distributed and dense. The horizontal front and back vibration and the vertical up and down vibration can be changed in order according to the needs, and can even be performed alternately. Moreover, the frequency amplitude excitation force in both directions can be adjusted independently, which reflects the advantages of the hydraulic system.

[0023] In the above concrete excitation forming process, one end of the forming mold 3 is first connected to the extended end of the horizontally arranged actuator 2 by a train automatic coupler 4, such as the automatic coupler 4 of the patented technology of Sifang Institute of my country. The automatic coupler 4 has the characteristics of reliable connection, small gap and full automatic. Adjust the speed of the 2D excitation valve 1, and start the front and rear vibration with a frequency of 60Hz and an amplitude of 100mm for 90s. Reduce the pressure of the high-pressure variable piston pump and increase the flow rate to achieve the above requirements. Then control the corresponding hydraulic valve to stop the horizontal actuator 2, and adjust the piston to return to the initial position through the slide valve type three-position five-way servo valve 7. Let the train automatic coupler 4 disengage to restore the freedom of the forming mold 3 in the forward direction. Through the sequential control loop, start the vertical vibration of another actuator 2. Adjust the speed of the 2D excitation valve 1 to start the up and down vibration with a frequency of 150Hz and an amplitude of 10mm for 60s. Increase the pressure of the variable piston pump and reduce the flow rate to achieve the above requirements.

[0024] Example 4: Fig.16 As shown, a concrete excitation molding equipment, two actuators 2 are arranged in a vertical direction, the actuator 2 is connected to the platform 8 and the displacement, frequency and amplitude vibration parameter settings must be kept consistent. Such an arrangement can realize the vertical vibration of a large molding mold 3. Under the synchronous control loop, it can vibrate with the same frequency, amplitude and phase, avoiding the asynchronous up and down vibrations causing greater noise and energy cancellation. Of course, before vibration, the piston needs to be adjusted by the sliding valve type three-position five-way servo valve 7 to return to the initial position to ensure the initial phase consistency of the synchronous actuator. The specific molding process is to adjust the rotation speed of the 2D excitation valve 1 to start the up and down vibration with a frequency of 120Hz and an amplitude of 15mm for 10s. Increase the pressure of the high-pressure variable piston pump and reduce the flow rate to achieve the above requirements.

[0025] It is obvious to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and can be implemented in other specific forms, such as increasing the number of vertical actuators and simply replacing the connection mode, without departing from the spirit or essential characteristics of the present invention. Therefore, no matter from which point of view, the embodiments should be regarded as exemplary and non-restrictive, and the scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes that fall within the meaning and range of the equivalent elements of the claims are included in the present invention. Any reference numerals in the claims should not be regarded as limiting the claims involved.

Claims

1. A concrete vibration forming device, comprising a control system, a vibration system and a forming mold (3), characterized in that The excitation system is an electro-hydraulic excitation system controlled by a 2D excitation valve (1), comprising an actuator (2) directly connected to a hydraulic source and a 2D excitation valve (1), wherein two oil ports of the 2D excitation valve are connected to high-pressure oil and return oil respectively.

2. A concrete vibration forming device, comprising a control system, a vibration system and a forming mold (3), characterized in that The excitation system is an electro-hydraulic excitation system controlled by a 2D excitation valve (1), comprising a hydraulic source and a plurality of actuators (2) connected to a 2D excitation valve (1) via a sequential control circuit or a synchronous circuit, wherein two oil ports of the 2D excitation valve (1) are connected to high-pressure oil and return oil respectively.

3. The concrete vibration forming equipment according to claim 1, characterized in that One end of the molding die (3) is connected to the protruding end of the actuator (2) by using an automatic coupler (4) for trains.

4. The concrete vibration forming equipment according to claim 1 or 2, characterized in that The forming mold (3) is equipped with wheels (3a) and is placed on the rails (5).

5. The concrete vibration forming equipment according to claim 1 or 2, characterized in that The molding die (3) is provided with a slide rail (3b) which is placed on a track groove (6) covered with cylindrical rollers (6a).

6. The concrete vibration forming equipment according to claim 2, characterized in that One of them The actuator (2) can be arranged in parallel along the forward direction of the molding die (3), and the remaining plurality of actuators (2) are arranged in a vertical direction. The actuator (2) is connected to the platform (8) and the displacement, frequency and amplitude vibration parameter settings must be kept consistent.

7. The concrete vibration forming equipment according to claim 1 or 2, characterized in that The hydraulic source is a high-pressure and high-power plunger pump.

8. The concrete vibration forming equipment according to claim 1, 2 or 7, characterized in that The actuator (2) is a piston cylinder and can be connected in parallel to a slide valve type three-position five-way servo valve (7).

9. The production process of concrete vibration molding as claimed in claims 1, 2 and 7, characterized in that The frequency can be adjusted to 50-200 Hz by adjusting the rotation speed of the valve core (1a) of the 2D excitation valve (1), and the axial displacement of the valve core (1a) can be adjusted steplessly to achieve an amplitude change in the range of 5-500 mm. The direction of the amplitude change is opposite to the frequency change, and the excitation molding time is 60-150 s.

10. The production process of concrete vibration molding as claimed in claims 2, 6 and 7, characterized in that The frequency, amplitude and vibration time of the forward and backward reciprocating vibration along the advancing direction of the molding die (3) and the upward and downward reciprocating vibration of the platform (8) can be adjusted independently, and the sequence of the vibrations can be switched.

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