Intelligent flow production line construction method for prefabricated meter-gauge rail sleepers

Abstract

The invention discloses an intelligent flow production line construction method for prefabricated meter gauge sleepers, and belongs to the technical field of sleeper production. In the production process of prefabricated meter gauge sleepers, the problems that the production process is not intelligent, parameters in all links are not accurately controlled, and the product quality is difficult to guarantee exist. In order to solve the problems, according to the construction method, concrete raw materials are conveyed into a double-spiral stirrer through a spiral conveyor to be stirred, and then operations such as injection into a mold vehicle, high-frequency vibration, steam curing and hydraulic demolding are conducted in sequence. Segmented gradient control is adopted in a heating area of the steam curing chamber, a three-stage humidity compensation mechanism is arranged in a constant temperature area, and dynamic balance cooling is implemented in a cooling area. According to the method, intelligent and precise control over prefabricated meter gauge sleeper production is achieved, the production efficiency and the product quality are effectively improved, and the method is mainly used for industrial production of prefabricated meter gauge sleepers.

Description

Technical Field

[0001] The invention belongs to the technical field of sleeper production, and in particular relates to a construction method for an intelligent production line of prefabricated meter-gauge sleepers. Background Art

[0002] In the production of prefabricated meter-gauge sleepers, traditional production methods face many problems that need to be solved, which seriously restrict the improvement of production efficiency and product quality. In the concrete mixing process, the single-screw mixer or ordinary mixing equipment commonly used in the past has poor mixing effect. Its mixing principle is simple, and it is difficult to fully mix the concrete raw materials, resulting in unstable concrete performance. For example, cement, aggregates and additives cannot be evenly dispersed, affecting the strength and durability of concrete. This is because the mixing blade structure and movement mode of the single-screw mixer are relatively simple, and it is impossible to mix materials in an all-round and high-intensity manner. Moreover, traditional mixing equipment lacks precision in mixing time control. Too long or too short mixing time will have an adverse effect on the quality of concrete, but it is difficult to find the optimal mixing time, making it difficult to ensure production quality. There are also problems in the process of injecting concrete into the mold car. In the past, it relied on manual operation or simple unloading devices, which could not ensure that concrete was evenly injected into the mold car. This will lead to uneven distribution of concrete in the mold car. During subsequent vibration, some areas are not vibrated densely, and defects such as cavities and honeycombs will appear, which seriously affects the structural strength of the sleeper. The manual operation method is not only inefficient, but also greatly affected by human factors. The differences in operating habits and skill levels of different operators further aggravate the problem of uneven injection. In the vibration stage, the excitation force and vibration frequency of traditional vibrating equipment are difficult to accurately control. If the excitation force is insufficient or the vibration frequency is inappropriate, the bubbles in the concrete cannot be fully discharged, and pores will be formed inside the sleeper, reducing the compressive strength and impermeability of the sleeper. In addition, the residence time of the mold car at the vibration station lacks scientific planning. If the residence time is too short, a good vibration effect cannot be achieved, and if it is too long, it will affect production efficiency. Due to the lack of real-time monitoring means of the state of concrete during the vibration process, it is difficult to adjust the vibration parameters according to the actual situation of the concrete. It can only rely on experience, resulting in uneven product quality. Steam curing is a key link in the production of sleepers, but traditional curing methods have many defects. In the heating stage, temperature control is mostly extensive, and it is impossible to achieve segmented gradient heating. It is easy for the sleeper to produce large thermal stress due to rapid temperature changes, resulting in defects such as cracks in the sleeper. During the constant temperature stage, the humidity and temperature are not precisely regulated, and there is a lack of effective humidity compensation mechanisms and temperature stabilization measures. When the humidity is not appropriate, the evaporation of moisture on the surface of the sleeper is too fast or too slow, which will affect the hydration reaction of the concrete and thus affect the strength development of the sleeper; large temperature fluctuations will also have an adverse effect on the quality of the sleeper. During the cooling stage, there was no technology for dynamic balanced cooling based on the temperature difference between the core and the surface of the sleeper, which caused cracks in the sleeper during the cooling process due to the large temperature difference between the inside and outside, seriously reducing the qualified rate of the product. In the demolding process, traditional demolding methods mostly use manual assistance or simple mechanical devices, which are not only inefficient, but also easy to damage the sleeper.For example, when using mechanical pushing to demould, the uneven pushing force can easily cause the sleepers to break or have their surfaces damaged during the demoulding process, increasing the scrap rate, resulting in waste of resources and increased costs. Summary of the invention

[0003] One purpose of the present invention is to solve the problems in the production process of traditional prefabricated meter-gauge sleepers, such as uneven concrete mixing, insufficient vibration, difficult to accurately control curing conditions, low demoulding efficiency and easy damage to sleepers, which leads to unstable product quality and low production efficiency. The present invention aims to solve these problems and realize the efficient and high-quality production of prefabricated meter-gauge sleepers.

[0004] During the cooling stage of steam curing of prefabricated meter-gauge sleepers, it is difficult to accurately control the cooling rate, and it is impossible to adjust in real time according to the temperature difference between the core and the surface of the sleeper, which easily causes cracks in the sleeper due to excessive temperature difference. The present invention solves the problem of inaccurate temperature control during the cooling process by establishing a simulation model and collecting temperature difference data in real time.

[0005] In the steam curing constant temperature zone, it is difficult to achieve precise control of temperature and humidity. The traditional method cannot timely and reasonably compensate and adjust according to humidity changes, which affects the concrete hydration reaction and the quality of the sleepers. The present invention aims to solve the problem of inaccurate temperature and humidity control in the constant temperature zone and ensure a stable sleeper curing environment.

[0006] When the temperature in the steam curing constant temperature zone fluctuates, the traditional method cannot quickly and accurately adjust the steam valve opening to maintain temperature stability. The present invention solves the problem of untimely and inaccurate steam valve adjustment when the temperature fluctuates through a specific algorithm.

[0007] In the steam curing heating zone, the traditional heating method cannot flexibly adjust the heating strategy according to the initial temperature of the mold car, and it is difficult to ensure the stability and accuracy of the heating process, which can easily cause excessive thermal stress on the sleeper or too long curing time. The present invention solves the problem of inflexible and inaccurate heating control in the heating zone.

[0008] It is difficult to ensure the accuracy and efficiency of sleeper quality inspection after demoulding by manual labor, and it is impossible to accurately detect and process sleeper surface defects and embedded casing deviation in real time. The present invention solves the problem of inaccurate and inefficient sleeper quality inspection through a visual inspection system and an AI recognition model.

[0009] In the production process of prefabricated meter-gauge sleepers, the setting of parameters of various equipment lacks scientific basis, which makes it difficult to achieve the best production efficiency and product quality. The present invention clarifies the parameters of various equipment and optimizes the production process.

[0010] In the steam curing cooling zone, it is impossible to perform fine temperature control on different areas, waste heat cannot be effectively recycled, and the temperature difference between adjacent areas is difficult to control. The present invention solves these problems by setting independent temperature control zones and waste heat recovery pipelines.

[0011] In the process of steam curing temperature control, when the temperature exceeds the tolerance, the traditional adjustment method is not precise enough, and when the temperature and humidity compensation requirements are triggered at the same time, the control sequence cannot be reasonably arranged. The present invention solves the problem of imprecise temperature excess adjustment and chaotic temperature and humidity control logic.

[0012] To this end, the present invention provides a construction method for a prefabricated meter-gauge sleeper intelligent production line, which comprises the following steps: The concrete raw materials are fed into the double-screw mixer through a screw conveyor. The two screw shafts of the double-screw mixer rotate in opposite directions. The mixing time is 3 to 5 minutes. The mixed concrete flows into the buffer hopper. An electromagnetic vibration feeder is set at the bottom of the buffer hopper to evenly inject the mixed concrete into the mold car below. The mold car injected with concrete enters the high-frequency vibrating station through the track. The vibrator adopts an eccentric block exciter to vibrate the concrete in the mold car. The mold car stays at the vibrating station for 30 to 50 seconds and then moves out. The vibrated mold car enters the steam curing room, which is divided into a heating zone, a constant temperature zone and a cooling zone. The mold car that has been cured is transported to the hydraulic demoulding station. The demoulding mechanism includes four sets of symmetrically arranged hydraulic jacking devices, which act on the side wall of the mold car synchronously through the four sets of hydraulic jacking devices to separate the molded sleeper from the mold car to obtain the demoulded sleeper. Among them, the heating zone adopts segmented gradient control, heating to 30℃ at a rate of 10℃ / h in the first 30 minutes, and then continuously heating to 65℃ at a rate of 18℃ / h. The total heating time is controlled within 3.5 - 4 hours; a three-level humidity compensation mechanism is set in the constant temperature zone. When the real-time humidity is lower than 85% of the preset value, the atomizing spray system is started. When it is higher than 95% of the preset value, the negative pressure dehumidification port is opened. When the temperature fluctuation exceeds the range of ±2℃, the steam valve opening is automatically adjusted. Dynamic balanced cooling is implemented in the cooling zone. The cooling rate is automatically adjusted according to the temperature difference between the core and the surface of the sleeper. When the temperature difference between the core and the surface is greater than 8℃, the cooling rate is reduced to 5℃ / h. When the temperature difference is ≤5℃, the standard rate of 10℃ / h is restored.

[0013] Preferably, the specific method for implementing dynamic balanced cooling in the cooling zone includes the following steps: synchronously collecting temperature difference data through a wireless temperature sensor pre-buried in the core of the sleeper and a surface contact thermocouple, and uploading it to the central control unit in a period of 30 seconds; establishing a simulation model of the temperature field of the sleeper cross section, and when the real-time value of the core-surface temperature difference ΔT>8°C, it is judged as a thermal stress risk state, and the central control unit sends a speed reduction instruction to the circulating air system in the cooling zone to reduce the cooling rate from 10°C / h to 5°C / h; when the real-time value of the core-surface temperature difference ΔT falls back to the range of 5°C≤ΔT≤8°C, maintain a cooling rate of 5°C / h; when ΔT≤5°C and remains stable for 20 minutes, restore the standard cooling rate of 10°C / h; during the dynamic cooling process, if the dispersion coefficient of the core-surface temperature difference of the same maintenance batch exceeds 0.25, an abnormal alarm is triggered and the mold vehicle is marked to enter the manual re-inspection queue.

[0014] Preferably, the specific implementation method of the three-level humidity compensation mechanism in the constant temperature zone includes the following steps: collecting multi-dimensional temperature and humidity data in the constant temperature zone in real time through distributed capacitive humidity sensors and PT100 temperature sensors, and transmitting them to the fuzzy PID controller at a frequency of 0.1Hz; when the relative humidity is detected to be lower than the preset value of 85%, starting the pulse modulation mode of the atomizing spray system: when the humidity deviation is ≤10%, intermittent spraying is performed at a duty cycle of 30%-50%; when the humidity deviation is greater than 10%, switching to continuous spraying and linking the circulating air system to enhance the uniformity of water mist diffusion; when the relative humidity is detected to be higher than the preset value of 95%, turning on the adaptive control of the negative pressure dehumidification port: dynamically adjusting the opening of the dehumidification port according to the humidity exceeding the standard, the opening ratio K =1.2×(Hreal-time-Htarget), H is the humidity percentage; synchronously reducing the air supply rate of the circulating air system to 60%-80% of the rated value to inhibit moisture diffusion.

[0015] Preferably, when the temperature fluctuation exceeds the range of ±2°C, dynamic adjustment is performed based on the steam valve opening compensation algorithm: when the temperature exceeds the tolerance in the positive direction, the steam valve opening is reduced at a ratio of ΔT×0.8% / °C; when the temperature exceeds the tolerance in the negative direction, the steam valve opening is increased at a ratio of ΔT×1.2% / °C; if humidity compensation and temperature compensation need to be triggered at the same time, the temperature control instruction is executed first, and the humidity compensation operation is performed after the temperature returns to within the threshold.

[0016] Preferably, the specific implementation method of the segmented gradient control in the heating zone includes the following steps: deploying an infrared temperature scanner at the entrance of the heating zone to obtain the initial temperature T0 of the mold vehicle surface in real time, and dynamically adjusting the subsequent heating rate reference value according to the initial temperature; activating the steam injection preheating module at startup to heat the temperature to 30°C at a constant rate of 10°C / h; when it is detected that the deviation between the actual temperature rise rate and the target rate exceeds ±1.5°C / h, the proportional-integral- The differential compound control algorithm dynamically adjusts the steam valve opening. The algorithm comprehensively calculates the compensation amount based on the real-time temperature difference deviation value, the accumulated deviation and the deviation change rate. When the front stage of heating is full for 30 minutes, if the measured temperature does not reach 28°C, the front stage of heating time is extended until the temperature reaches the standard and the total duration does not exceed 45 minutes. If the measured temperature exceeds 32°C, the subsequent heating rate is automatically reduced to 15°C / h. A variable rate climbing strategy is adopted. The temperature is increased at a rate of 18°C / h in the initial stage, and the remaining heating time is recalculated every 10 minutes based on the temperature field simulation prediction model. When the predicted total duration will exceed the upper limit of 4 hours, the steam flow rate is increased in steps according to the proportional relationship between the remaining temperature difference and the remaining time. When the temperature reaches 63°C, it is switched to the incremental approximation mode, and the heating rate is reduced to 2°C / h for fine-tuning until the temperature stabilizes within the range of 65°C±0.5°C.

[0017] Preferably, the construction method of the intelligent assembly line for prefabricated meter-gauge sleepers also includes: the sleepers after demoulding are scanned by a visual inspection system, the inspection system includes 3 groups of industrial cameras, and the inspection data are transmitted to the central control unit in real time; wherein, the surface image and dimensional data are synchronously collected by three groups of industrial cameras arranged above and on both sides of the sleepers, wherein: the upper camera detects surface cracks and bubble defects; the cameras on both sides detect the position offset of the embedded casing; the collected data is input into the AI ​​recognition model, and the following indicators are judged in real time whether they are qualified: when the surface defect area exceeds 0.3%, it is marked as a defective product; when the embedded casing offset exceeds ±1.5mm, it is marked as a returned product; the inspection results are transmitted to the central control unit in real time, and if defective products or returned products appear: a defect type report is automatically generated and an audible and visual alarm is triggered; a QR code containing production information is automatically engraved on qualified sleepers, and the inspection data is encrypted and uploaded to the quality traceability platform.

[0018] Preferably, the double-screw mixer conveys concrete at a conveying speed of 3.5 m / s, the screw shaft speed is 25 rpm, and the inclination angle of the mixing blade is 45°; the mixed concrete flows into the buffer hopper through the air pressure valve control; the electromagnetic vibration frequency of the electromagnetic vibration feeder is 50 Hz, and the vibration amplitude is 2 mm; the mold car intermittently steps on the track at a speed of 0.8 m / s, and the steel bar skeleton is preset in the mold car and fixed by a magnetic positioning device, and the magnetic positioning device generates a uniform magnetic field of 0.5 T; the mold car injected with concrete enters the high-frequency vibration station through the track, and the vibrator adopts an eccentric block exciter with an exciting force of 12 kN and a vibration frequency of 120 Hz to vibrate the concrete in the mold car, and the mold car stays at the vibration station for 30 - Move out after 50 seconds; in the hydraulic jacking device, the single-group jacking force is 8 tons, the jacking stroke is 200mm, and the jacking speed is 5mm / s; among them, the bottom of the mold car is also equipped with an automatic lubricant spraying device, the spraying pressure is 0.3MPa, and the spraying volume is 0.2L / m².

[0019] Preferably, the implementation method of dynamic balanced cooling in the cooling zone further includes: setting independent temperature control zones at intervals of 2 meters along the track direction of the maintenance room, and deploying insulation curtains on the top of each zone; the waste heat recovery pipeline is set at the top of the maintenance room, and the end of the pipeline branch extends to the top of each temperature control zone, and each branch pipeline is installed with an electric regulating valve, and the opening of the regulating valve is dynamically associated with the temperature difference of the sleeper core surface of the corresponding zone; when the core surface temperature difference is greater than 8°C, the following linkage operations are performed: triggering the insulation curtain closing instruction of the corresponding zone to form a semi-enclosed insulation space for the zone; synchronously increasing the opening of the waste heat recovery pipeline regulating valve of the zone to 50%-70%, and directionally transmitting the recovered waste heat back to the zone; when the core surface temperature difference is ≤5°C, performing the following operations: opening the insulation curtain in stages, first maintaining an opening of 30% for 5 minutes and then fully opening it; closing the waste heat recovery pipeline regulating valve of the corresponding zone, and starting the fresh air replacement system to eliminate local temperature and humidity gradients; the control data of each zone is mapped to the three-dimensional thermal field simulation interface in real time, and automatically inserting a transition buffer zone when the temperature difference between adjacent zones is greater than 3°C.

[0020] Preferably, when the temperature exceeds the tolerance in the positive direction ΔT>+2℃, the steam valve opening is adjusted in three stages based on the tolerance amplitude: when ΔT≤3℃, the opening is reduced by 1.2% for every 1℃ excess; when 3℃<ΔT≤5℃, the opening is reduced by 1.5% for every 1℃ excess; when ΔT>5℃, the emergency shutdown procedure is triggered to cut off the steam supply and start forced heat dissipation; when the temperature exceeds the tolerance in the negative direction (ΔT<-2℃), the opening is increased by 2% for every 1℃ deficiency, and the increase is linearly accumulated with the duration of the deficiency; and when the temperature and humidity compensation requirements are triggered at the same time, the system automatically executes the following The following logic: Freeze the humidity compensation instruction and store it in the queue to be executed; prioritize temperature compensation until ΔT returns to the range of ±1.5℃; activate humidity compensation after a delay of 5 minutes, and associate the compensation amount with the historical temperature control data; and, when the temperature approaches the threshold of ±1℃, pre-adjust the steam valve opening in advance at the ratio of ΔT×0.5% / ℃; when the temperature has not returned to the threshold after three consecutive adjustments, trigger the neural network prediction model to optimize the compensation coefficient; if the single temperature compensation amplitude exceeds 30% of the total steam valve opening, it is judged as a sensor failure and switched to the backup temperature control mode.

[0021] Preferably, in the construction method of the prefabricated meter-gauge sleeper intelligent production line, the dynamic adjustment method of the proportional-integral-differential composite control algorithm includes the following steps: The temperature rise rate deviation value e(t) is calculated in real time. When |e(t)|>1.5℃ / h, the PID controller control mode is activated. The proportional coefficient Kp is adjusted in real time according to the current deviation value. When the deviation is greater than 3℃ / h, Kp is increased to 1.5 times the reference value, and when the deviation is less than 1℃ / h, the reference value is restored; When the accumulated deviation integral reaches the preset threshold, the integral term is automatically reset and the integral coefficient Ki is reduced to 0.8 times to prevent overshoot; Dynamically correct the differential coefficient Kd based on the deviation change rate. When the change rate is greater than 0.5℃ / h², Kd increases to 1.2 times the reference value. The steam valve opening compensation ΔV is generated according to the weighted Kp, Ki, and Kd. The compensation calculation formula is: ΔV=Kp×e(t) + Ki×∫e(t)dt + Kd×de(t) / dt; Apply ±15% limit protection to ΔV to avoid valve jump; When the valve opening is at the limit position (>95% or <5%) for 5 minutes and the deviation has not converged, the integral term is frozen and switched to fuzzy control mode; After each adjustment, the temperature rate change in the subsequent 10 minutes is monitored. If the deviation convergence rate is less than 60%, the PID parameter self-tuning program is automatically triggered.

[0022] Beneficial effects: Through a series of precisely controlled processes such as double-screw mixer, electromagnetic vibration feeder, high-frequency vibration, steam curing and hydraulic demoulding, the concrete is mixed evenly, vibrated densely, cured reasonably, and demoulding efficiently and without damage, which greatly improves the quality stability of prefabricated meter-gauge sleepers, while optimizing the production process, improving production efficiency and reducing production costs.

[0023] Using wireless temperature sensors and thermocouples to collect temperature difference data and adjusting the cooling rate in combination with simulation models can effectively prevent cracks in sleepers caused by excessive temperature difference between the core and the surface, improve the structural strength and durability of sleepers, reduce scrap rate, improve product quality, and ensure the safety and reliability of prefabricated meter-gauge sleepers in actual use.

[0024] Distributed temperature and humidity sensors work with fuzzy PID controllers to achieve precise control of humidity in the constant temperature zone. Reasonable spraying and dehumidification operations ensure the smooth progress of concrete hydration reaction, which is beneficial to improving the strength of sleepers, reducing quality defects caused by humidity problems, and ensuring stable sleeper quality.

[0025] The steam valve opening compensation algorithm can quickly respond to temperature fluctuations, adjust the steam volume in time, and maintain the temperature stability in the constant temperature zone. The logic of giving priority to the execution of temperature control instructions avoids conflicts between temperature and humidity control, ensures a stable maintenance environment, and provides suitable conditions for concrete hydration reaction, thereby improving the quality of sleepers.

[0026] The heating strategy is adjusted according to the initial temperature of the mold car, and a variety of control algorithms and rate adjustment methods are combined to ensure a stable and accurate heating process. This can not only prevent the sleeper from thermal stress cracks due to rapid temperature changes, but also reasonably control the maintenance time, improve production efficiency, and ensure the quality of the sleeper.

[0027] The visual inspection system and AI recognition model realize the automated and high-precision inspection of sleeper quality. It can quickly and accurately identify surface defects and embedded casing deviation, handle defective products and returned products in a timely manner, improve inspection efficiency and accuracy, and facilitate the full-process monitoring and management of product quality through the quality traceability platform.

[0028] Clarify the parameters of each equipment to optimize the matching of each link in the production process. Ensure the efficient and stable operation of concrete transportation, mixing, vibration, demoulding, etc., improve production efficiency, and help improve the consistency and stability of product quality.

[0029] The setting of independent temperature control zones, thermal insulation curtains and waste heat recovery pipes realizes refined temperature control and waste heat recovery in the cooling zone. It reduces the temperature difference between adjacent areas, avoids the influence of local temperature and humidity gradients on the quality of sleepers, improves energy utilization and reduces production costs.

[0030] The graded adjustment of steam valve opening and multiple temperature control logics make the adjustment more precise and reasonable when the temperature exceeds the tolerance. The optimization of compensation coefficients combined with the neural network prediction model can better cope with complex temperature changes, improve the accuracy and reliability of temperature control, ensure the stability of the maintenance process, and improve the quality of sleepers. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 This is a schematic diagram of an embodiment of the present application.

[0032] Figure numerals: 1, double-screw mixer; 2, buffer hopper; 3, mold car; 4, track; 5, vibrator; 6, steam curing room; 7, hydraulic demoulding station. DETAILED DESCRIPTION

[0034] The present invention is further described in detail below in conjunction with the accompanying drawings so that those skilled in the art can implement the invention with reference to the description.

[0035] According to one embodiment of the present invention, in the concrete mixing and conveying link, the concrete raw materials can be sourced from common building material suppliers. The screw conveyor 1 can select the existing U-shaped screw conveyor on the market, and its conveying capacity and pipe diameter can be selected according to actual production needs. The double-screw mixer 1 can select a mixer with a double screw shaft and capable of reverse rotation, such as a certain brand of forced double-screw mixer. The mixing time can be selected between 3 minutes and 5 minutes, for example, 3 minutes, 4 minutes, and 5 minutes. This parameter setting can be determined through preliminary tests based on the characteristics of the concrete raw materials. The mixed concrete flows into the buffer hopper 2 through an air pressure valve control. The air pressure valve can select a pneumatic butterfly valve made of stainless steel, which has good opening and closing speed and sealing.

[0036] When concrete is injected into the mold, an electromagnetic vibrating feeder is installed at the bottom of the buffer hopper 2. The electromagnetic vibrating feeder can be selected with a vibration frequency of 50Hz and a vibration amplitude of 2mm, such as a standard electromagnetic vibrating feeder produced by a certain manufacturer. The mold car 3 can be a steel mold car with a pre-set steel skeleton inside and fixed by a magnetic positioning device. The magnetic positioning device can generate a 0.5T uniform magnetic field to ensure the accurate position of the steel skeleton. The mold car 3 intermittently steps on the track 4 at a speed of 0.8m / s. The track 4 can use a standard light rail track to ensure the smooth operation of the mold car 3.

[0037] When the concrete is vibrated, the mold vehicle 3 injected with concrete enters the high-frequency vibrating station. The vibrator 5 adopts an eccentric block vibrator with an exciting force of 12kN and a vibration frequency of 120Hz. For example, a certain type of eccentric block vibrator can meet the requirements. The mold vehicle 3 stays at the vibrating station for 30-50 seconds, such as 30 seconds, 40 seconds, and 50 seconds. The specific time can be determined according to the slump and other characteristics of the concrete. After the vibration is completed, it enters the steam curing room 6, which is divided into a heating zone, a constant temperature zone, and a cooling zone. The heating zone adopts segmented gradient control, and the temperature is raised to 30℃ at a rate of 10℃ / h in the first 30 minutes, and then continues to rise to 65℃ at a rate of 18℃ / h. The total heating time is controlled within 3.5-4 hours. A three-level humidity compensation mechanism is set in the constant temperature zone, and the temperature and humidity are monitored by sensors and related equipment are controlled. The cooling zone implements dynamic balanced cooling, and the cooling rate is automatically adjusted according to the temperature difference between the core and the surface of the sleeper. After the curing is completed, the mold car 3 is transported to the hydraulic demoulding station 7. The demoulding mechanism includes four groups of symmetrically arranged hydraulic jacking devices, with a single group of 8 tons of jacking force, a jacking stroke of 200mm, and a jacking speed of 5mm / s. The hydraulic jacking equipment that meets the parameter requirements can be selected. Finally, the molded sleeper is separated from the mold car 3 to obtain the demoulded sleeper.

[0038] Through the above specific implementation methods, it is possible to ensure uniform mixing of concrete and improve the workability and strength of concrete. The process of injecting concrete into the mold is accurately controlled to ensure uniform distribution of concrete and reduce internal defects. High-frequency vibration can effectively expel bubbles in the concrete and improve the density of the sleeper. Accurate temperature and humidity control during steam curing is conducive to the hydration reaction of concrete and enhances the strength and durability of the sleeper. The hydraulic demoulding method is efficient and can avoid damage to the sleeper, which improves production efficiency and product quality, so that prefabricated meter-gauge sleepers can better meet the requirements of engineering use.

[0039] According to another embodiment of the present invention, the temperature difference data is collected synchronously by the wireless temperature sensor pre-buried in the core of the sleeper and the surface contact thermocouple, and uploaded to the central control unit. Adjustment of cooling rate: Based on the real-time value of the core-surface temperature difference, the central control unit controls the cooling zone circulating air system to adjust the cooling rate using the simulation model of the sleeper cross-section temperature field. Abnormal alarm and processing: When the core-surface temperature difference dispersion coefficient of the sleeper of the same maintenance batch exceeds 0.25, an abnormal alarm is triggered and the mold vehicle 3 is marked to enter the manual re-inspection queue.

[0040] In terms of temperature difference data collection, wireless temperature sensors can choose products with high-precision measurement and wireless transmission functions on the market, such as a wireless temperature sensor suitable for measuring the internal temperature of concrete, which can adapt to the complex environment inside the concrete and work stably. Surface contact thermocouples can use K-type thermocouples with high accuracy and fast response speed. They are made of nickel-chromium-nickel-silicon alloy and can accurately measure the surface temperature of the sleeper. The data collection cycle of these sensors is 30 seconds. This value has been determined after many tests, which not only ensures the timeliness of data updates, but also does not increase the system data processing burden too much. The wireless temperature sensor is embedded in the core of the sleeper, and the surface contact thermocouple is installed on the surface of the sleeper. The temperature difference data they collect is uploaded to the central control unit in a cycle of 30 seconds. The central control unit can use an industrial control computer with powerful data processing and analysis capabilities.

[0041] For the adjustment of the cooling rate, we must first establish a simulation model of the temperature field of the sleeper section. This model can be constructed based on the finite element analysis principle and using existing professional simulation software. When the real-time value of the core-surface temperature difference ΔT>8°C, the central control unit sends a speed reduction instruction to the cooling zone circulating air system. The fan in the cooling zone circulating air system can select an axial flow fan with variable frequency to adjust the wind speed. The speed is adjusted according to the instruction to change the cooling rate, reducing the cooling rate from 10°C / h to 5°C / h. When the real-time value of the core-surface temperature difference ΔT falls back to the range of 5°C≤ΔT≤8°C, maintain a cooling rate of 5°C / h; when ΔT≤5°C and remains stable for 20 minutes, restore the standard cooling rate of 10°C / h. These thresholds and time settings are obtained by analyzing and summarizing a large amount of temperature change data during sleeper maintenance.

[0042] In the abnormal alarm and processing link, in order to calculate the temperature difference dispersion coefficient of the sleeper core surface of the same maintenance batch, it is necessary to collect the temperature difference data of all sleepers in the batch in real time. The data acquisition card can be used to collect the data of each sensor and transmit it to the central control unit for calculation. When the dispersion coefficient exceeds the threshold of 0.25, the central control unit triggers an abnormal alarm. The alarm device can choose an audible and visual alarm and install it in a conspicuous position in the maintenance area to facilitate timely detection by staff. At the same time, the system will mark the abnormal mold car 3 to enter the manual re-inspection queue, which is convenient for staff to conduct subsequent key inspections on the sleepers produced by the mold car 3 to ensure product quality.

[0043] Through the above implementation, the temperature difference data between the core and the surface of the sleeper can be collected in real time and accurately, providing a reliable basis for the subsequent adjustment of the cooling rate. The cooling rate is adjusted in time according to the temperature difference change, which effectively avoids the occurrence of thermal stress cracks in the sleeper due to excessive temperature difference between the core and the surface, and improves the structural stability and quality of the sleeper. The abnormal alarm and manual re-inspection mechanism can timely detect abnormal conditions during the maintenance process, further ensuring the quality consistency of each batch of sleepers, reducing the scrap rate, reducing production costs, and enabling the prefabricated meter-gauge sleepers produced to better meet the requirements of engineering use.

[0044] According to another embodiment of the present invention, multi-dimensional temperature and humidity data in the constant temperature zone are collected in real time through distributed capacitive humidity sensors and PT100 temperature sensors, and transmitted to the fuzzy PID controller. Control when humidity is low: When the relative humidity is detected to be lower than the preset value of 85%, the pulse modulation mode of the atomizing spray system is started for humidity compensation. Control when humidity is high: When the relative humidity is detected to be higher than the preset value of 95%, the negative pressure dehumidification port is opened and the circulating air system is regulated.

[0045] In terms of temperature and humidity data collection, capacitive humidity sensors can choose products with higher measurement accuracy on the market, such as a certain brand of capacitive humidity sensors, whose measurement accuracy can reach ±2%RH, which can effectively meet the humidity measurement needs in the constant temperature zone. The PT100 temperature sensor can use the conventional industrial platinum resistance temperature sensor, which is made of platinum and has high measurement accuracy and good stability. These sensors are distributed in the constant temperature zone and evenly installed in various key positions in the maintenance room, such as walls and tops, to comprehensively and accurately collect temperature and humidity data. The collected data is transmitted to the fuzzy PID controller at a frequency of 0.1Hz. The fuzzy PID controller can choose a highly integrated industrial control module, which can quickly process the input temperature and humidity data and output control signals.

[0046] When the relative humidity is detected to be lower than the preset value of 85%, the pulse modulation mode of the atomizing spray system is started. The nozzles in the atomizing spray system can be selected as solid cone nozzles that can produce fine water mist, and the material can be stainless steel to ensure corrosion resistance. When the humidity deviation is ≤10%, intermittent spraying is carried out at a duty cycle of 30%-50%. For example, the duty cycle can be selected as 30%, 40%, and 50%. This is determined through the previous spraying test under different humidity deviations to achieve the best humidity compensation effect; when the humidity deviation is greater than 10%, it is switched to continuous spraying and linked to the circulating air system to enhance the uniformity of water mist diffusion. The fan in the circulating air system can select an axial flow fan with suitable air volume and air pressure, which can be installed on the top or side of the curing room to ensure that the water mist can be evenly diffused in the curing room.

[0047] When the relative humidity is detected to be higher than the preset value of 95%, the adaptive regulation of the negative pressure dehumidification port is turned on. The negative pressure dehumidification port can select a dehumidification device with an electric regulating valve, and dynamically adjust the opening of the dehumidification port according to the humidity exceeding the standard. The opening ratio K= 1.2×(H real-time - H target), H is the humidity percentage. For example, when the humidity exceeds the standard by 10%, the opening ratio of the dehumidification port is 12%. At the same time, the air supply rate of the circulating air system is synchronously reduced to 60%-80% of the rated value to inhibit moisture diffusion. This control method is based on the study of the humidity change law and a large number of experiments, and can effectively control the humidity in the constant temperature zone.

[0048] Through the above specific implementation methods, the temperature and humidity data in the constant temperature zone can be collected in real time and comprehensively, providing an accurate basis for humidity control. When the humidity is low, the pulse modulation mode of the atomizing spray system can accurately compensate for the humidity, ensuring that the concrete hydration reaction has a suitable humidity environment. When the humidity is high, the coordinated regulation of the negative pressure dehumidification port and the circulating air system can discharge excess moisture in time to avoid the normal hydration reaction of the concrete being affected by excessive humidity. These measures work together to ensure the stability of the humidity in the constant temperature zone, which is conducive to improving the quality of prefabricated meter-gauge sleepers, reducing product defects caused by humidity problems, and improving production stability and reliability.

[0049] According to another embodiment of the present invention, it is determined whether the temperature fluctuation exceeds the range of ±2°C. Steam valve opening adjustment: According to the direction and size of the temperature deviation, the steam valve opening is dynamically adjusted based on the steam valve opening compensation algorithm. Temperature and humidity compensation priority: When humidity compensation and temperature compensation need to be triggered at the same time, determine the compensation operation to be performed first.

[0050] In the temperature deviation judgment link, it is necessary to monitor the temperature in the curing room in real time. The PT100 temperature sensor can be used to measure the temperature. The PT100 temperature sensor uses the characteristics of platinum resistance changing with temperature to accurately measure the temperature. It has the characteristics of high precision and good stability and is widely used in the field of industrial temperature measurement. It can be installed in different positions of the steam curing room 6, such as the area close to the mold car 3, the corner of the curing room, etc., to fully obtain the indoor temperature data. The collected temperature data is transmitted to the control system in real time, and the control system determines whether the temperature deviates according to the set ±2℃ threshold. This threshold is determined after analyzing a large amount of experimental data and actual production experience. Within this range, the concrete curing effect can be guaranteed while avoiding frequent adjustment of equipment parameters.

[0051] When it is determined that the temperature fluctuation exceeds the threshold range, the steam valve opening is adjusted according to the steam valve opening compensation algorithm. The steam valve can select an electric control valve, which can accurately adjust the valve opening according to the signal sent by the control system. When the temperature exceeds the tolerance in the positive direction, the steam valve opening is reduced by ΔT×0.8% / ℃. For example, if the temperature exceeds the set value by 3℃, the steam valve opening is reduced by 3×0.8% = 2.4%. When the temperature exceeds the tolerance in the negative direction, the steam valve opening is increased by ΔT×1.2% / ℃. If the temperature is 2℃ lower than the set value, the steam valve opening is increased by 2×1.2% = 2.4%. The steam valve is installed on the steam transmission pipeline to adjust the temperature in the curing room by controlling the steam flow rate. The parameter setting of this adjustment method is based on the study of the relationship between steam flow and temperature change, and is determined after multiple experimental verifications. It can effectively stabilize the temperature in the curing room.

[0052] When humidity compensation and temperature compensation need to be triggered at the same time, the temperature control instruction shall be executed first. This is because temperature has a more direct and critical impact on the hydration reaction of concrete. Unstable temperature may cause defects in the internal structure of concrete and affect the quality of the sleeper. Therefore, the system will first perform the temperature compensation operation until the temperature returns to the threshold of ±2°C, and then perform the humidity compensation operation. In actual operation, the control system will determine whether the two compensation requirements are triggered at the same time based on the temperature and humidity data collected by the sensor. If triggered at the same time, the control system will issue an instruction to control the steam valve to adjust the temperature first, and then control the corresponding equipment to perform humidity compensation according to the humidity conditions after the temperature stabilizes, such as controlling the atomizing spray system or the negative pressure dehumidification port. Such a priority setting ensures the stability of the temperature and humidity environment during the maintenance process, which is conducive to improving the quality of prefabricated meter-track sleepers.

[0053] Through the above-mentioned specific implementation method, the temperature change in the steam curing chamber 6 can be monitored in real time and accurately. When the temperature fluctuates, the steam valve opening is adjusted in time based on the steam valve opening compensation algorithm, which effectively stabilizes the temperature in the curing chamber and provides a suitable temperature environment for the hydration reaction of concrete. At the same time, the clear priority of temperature and humidity compensation avoids conflicts in the temperature and humidity control process and ensures the stability of the curing process. This series of measures helps to improve the quality of prefabricated meter-gauge sleepers, reduce product defects caused by temperature fluctuations and improper temperature and humidity control, improve production efficiency and product qualification rate, and enable the produced sleepers to better meet the requirements of engineering use.

[0054] According to another embodiment of the present invention, the initial surface temperature of the mold vehicle 3 is obtained at the entrance of the heating zone, and the heating rate reference value is dynamically adjusted accordingly. Temperature control during the startup phase: When starting, the temperature is raised to 30°C at a constant rate of 10°C / h, and the steam valve opening is adjusted according to the actual heating rate deviation. Abnormal processing of the front-end heating: When the front-end heating is completed for 30 minutes, the subsequent heating strategy is adjusted according to the measured temperature. Variable rate climbing and fine-tuning: The temperature is raised using a variable rate climbing strategy, and fine-tuning is performed when approaching the target temperature.

[0055] An infrared temperature scanner can be installed at the entrance of the heating zone to obtain the initial surface temperature of the mold car 3 in real time. The infrared temperature scanner can be selected with high precision and fast response characteristics, such as a certain brand of industrial-grade infrared temperature scanner, which can adapt to the factory environment and accurately measure the temperature. The subsequent heating rate reference value is dynamically adjusted according to the initial temperature. If the initial temperature is low, the heating rate reference can be appropriately increased; if the initial temperature is high, the heating rate reference is reduced. At startup, the steam injection preheating module starts to work and heats up to 30°C at a constant rate of 10°C / h. The steam injection preheating module can be composed of a steam nozzle, a pipeline and a control valve. The steam nozzle can be selected to be a model that can evenly spray steam and is installed on the top or side of the heating zone to ensure that the steam can evenly cover the mold car 3. During the heating process, the actual temperature rise rate is monitored in real time. When the deviation between the actual temperature rise rate and the target rate is detected to exceed ±1.5°C / h, the steam valve opening is dynamically adjusted through the proportional-integral-differential compound control algorithm. The steam valve can be an electric regulating valve installed on the steam delivery pipeline to facilitate the control of steam flow. The algorithm calculates the compensation amount based on the real-time temperature difference deviation value, deviation accumulation and deviation change rate to achieve precise temperature control.

[0056] When the front section is heated for 30 minutes, if the measured temperature does not reach 28°C, the front section heating time is extended until the temperature reaches the standard, and the total time does not exceed 45 minutes. If the measured temperature exceeds 32°C, the subsequent heating rate is automatically adjusted down to 15°C / h. The temperature measurement relies on the temperature sensor installed in the heating zone, such as the PT100 temperature sensor, which can be installed near the mold car 3 or at a key position in the heating zone to accurately measure the temperature. Through the analysis of a large amount of experimental data, the two thresholds of 28°C and 32°C are determined to ensure that the heating process is neither too slow to affect production efficiency nor too fast to cause thermal stress problems in the sleeper. A variable rate climbing strategy is adopted. The temperature is heated at a rate of 18°C / h in the initial stage, and the remaining heating time is recalculated every 10 minutes based on the temperature field simulation prediction model. The temperature field simulation prediction model can be constructed based on finite element analysis software, and the temperature distribution and changes during the heating process are simulated by computer to provide a basis for adjusting the heating rate.

[0057] When the total predicted duration exceeds the upper limit of 4 hours, the steam flow rate is increased in steps according to the ratio of the remaining temperature difference to the remaining time. This can be achieved by gradually increasing the opening of the steam valve, and the adjustment of the steam valve opening is automatically controlled by the control system based on the calculation results. When the temperature reaches 63°C, it switches to the incremental approximation mode and reduces the heating rate to 2°C / h for fine-tuning until the temperature stabilizes within the range of 65°C±0.5°C. The temperature sensor continuously monitors the temperature. When the temperature approaches 65°C, the steam valve opening is precisely adjusted to slowly increase the temperature and stabilize within the target range. This fine-tuning method can prevent the temperature from exceeding the target value and ensure the accuracy of the heating process.

[0058] Through the above implementation, the heating strategy can be flexibly adjusted according to the initial temperature of the mold vehicle 3, avoiding the problem of unreasonable heating caused by different initial conditions. Accurate heating rate control and abnormal handling mechanism prevent the impact of too fast or too slow heating on the quality of the sleeper, and reduce the risk of cracks in the sleeper due to thermal stress. The variable rate climbing and incremental approximation fine-tuning method makes the heating process more accurate, ensuring that the final temperature is stable within the target range, providing a suitable temperature environment for the hydration reaction of concrete, and improving the quality and production efficiency of prefabricated meter-gauge sleepers.

[0059] According to another specific embodiment of the present invention, the demoulded sleeper is scanned by a visual inspection system including three sets of industrial cameras, and the inspection data is transmitted to the central control unit in real time. The upper camera detects surface cracks and bubble defects, and the cameras on both sides detect the position offset of the embedded casing. The collected data is input into the AI ​​recognition model to determine whether the sleeper is qualified, and different inspection results are processed accordingly.

[0060] After demoulding, the sleeper enters the visual inspection area, and the visual inspection system starts working. The three groups of industrial cameras in the system can be selected from products with high resolution and suitable for industrial inspection environments. For example, the upper camera can choose a brand of 5-megapixel resolution area array camera, and its lens can use a wide-angle lens with a field of view that can cover the surface of the sleeper. It is installed just above the sleeper, about 1-2 meters away from the sleeper surface, to ensure that cracks and bubble defects on the sleeper surface can be clearly captured. The cameras on both sides can choose the same high-resolution linear array camera, and the lens can use a telephoto lens that can focus on the position of the embedded casing. They are installed on both sides of the sleeper, and the distance from the side of the sleeper is adjusted according to the actual situation to ensure that the embedded casing can be accurately captured. The image data collected by these three groups of cameras are transmitted to the central control unit in real time via data cables. The data cables can choose high-speed industrial-grade data cables to ensure the stability and timeliness of data transmission.

[0061] The upper camera is responsible for detecting cracks and bubble defects on the surface of the sleeper. During the inspection process, the image taken by the camera is transmitted to the central control unit, and the image is analyzed using an image recognition algorithm. If the surface defect area in the image exceeds 0.3%, it will be marked as a defective product. This 0.3% threshold is determined by analyzing a large number of qualified and unqualified sleeper samples and combining the requirements of the sleeper quality in actual projects. The cameras on both sides mainly detect the position offset of the embedded casing. By taking images of the embedded casing, the position information of the embedded casing is calculated using image measurement technology. If the offset of the embedded casing exceeds ±1.5mm, it will be marked as a repair product. This ±1.5mm threshold is also determined based on engineering standards and actual usage needs.

[0062] The collected image data is input into the AI ​​recognition model, which has been trained with a large amount of sleeper image data and can accurately determine whether various indicators are qualified. If the test results show that the sleeper is defective or returned for repair, the central control unit will automatically generate a defect type report. The report content includes information such as the specific location, type and severity of the defect, and triggers the sound and light alarm to remind the staff to deal with it in time. For qualified sleepers, the system will automatically engrave a QR code containing production information. The QR code can be laser engraved in a conspicuous position on the surface of the sleeper. At the same time, the test data will be encrypted and uploaded to the quality traceability platform. The quality traceability platform can choose a mature enterprise-level quality traceability system on the market to record and query the production process and quality information of the sleepers, so as to facilitate the full monitoring and management of product quality.

[0063] Through such a visual inspection system and processing flow, the quality of the demoulding sleepers can be quickly and accurately inspected. Compared with manual inspection, it improves the inspection efficiency and accuracy, and reduces the errors caused by human factors. Timely detection of defective and returned products prevents unqualified products from flowing into subsequent links, ensuring product quality. QR code engraving and data uploading to the quality traceability platform facilitates the traceability and management of product quality, helps enterprises improve their production management level, provides reliable guarantee for the production quality of prefabricated meter-gauge sleepers, and meets the strict requirements of the project for sleeper quality.

[0064] According to another embodiment of the present invention, the conveying speed, screw shaft speed, stirring blade inclination of the double-screw mixer 1, and the control method of mixing the concrete into the buffer hopper 2. The running speed of the mold vehicle 3 on the track 4, the fixing method of the steel bar skeleton in the vehicle, and the parameters of the electromagnetic vibration feeder. The parameters of the vibrator 5 of the high-frequency vibrating station, the parameters of the hydraulic jacking device, and the parameters of the automatic lubricant spraying device at the bottom of the mold vehicle 3.

[0065] In the concrete mixing and conveying link, the double-screw mixer 1 can choose industrial equipment with good mixing performance. Its conveying speed is 3.5m / s, the screw shaft speed is 25rpm, and the inclination angle of the mixing blade is 45°. Such parameter settings are determined through experiments on different mixing effects, which can fully mix the concrete raw materials. The mixed concrete flows into the buffer hopper 2 through the air pressure valve control. The air pressure valve can be a pneumatic butterfly valve made of stainless steel. It is installed on the conveying pipeline between the mixer and the buffer hopper 2. The valve is opened and closed by controlling the air pressure to achieve control of the concrete flow. The concrete raw materials can be sourced from nearby regular building materials suppliers to ensure that their quality meets production requirements.

[0066] The mold cart 3 steps intermittently on the track 4 at a speed of 0.8m / s. The track 4 can adopt a standard light rail track, which is installed on the floor of the production workshop to provide a stable running path for the mold cart 3. A steel skeleton is pre-installed in the mold cart 3 and fixed by a magnetic positioning device. The magnetic positioning device can generate a uniform magnetic field of 0.5T. The magnetic positioning device is installed at a specific position inside the mold cart 3 to ensure that the steel skeleton is accurately positioned in the mold cart 3. The electromagnetic vibration feeder is installed at the bottom of the buffer hopper 2, and its electromagnetic vibration frequency is 50Hz and the vibration amplitude is 2mm. When working, the electromagnetic vibration feeder evenly injects the concrete in the buffer hopper 2 into the mold cart 3 to ensure that the concrete is evenly distributed in the mold cart 3.

[0067] The mold car 3 injected with concrete enters the high-frequency vibration station, and the vibrator 5 adopts an eccentric block type vibrator with an exciting force of 12kN and a vibration frequency of 120Hz. The eccentric block type vibrator is installed on a specific bracket of the vibration station and fixed by bolts and other connecting parts to ensure that it is stable and reliable during operation. The mold car 3 stays at the vibration station for 30-50 seconds, such as 30 seconds, 40 seconds, and 50 seconds. The specific time can be determined according to the slump and other characteristics of the concrete. After the vibration is completed, the mold car 3 is transported to the hydraulic demoulding station 7. In the hydraulic jacking device, the single-group jacking force is 8 tons, the jacking stroke is 200mm, and the jacking speed is 5mm / s. The hydraulic jacking device is symmetrically installed at the corresponding positions of the two side walls of the mold car 3, and the molded sleeper is separated from the mold car 3 through synchronization. The bottom of the mold car 3 is also provided with an automatic lubricant spraying device with a spraying pressure of 0.3MPa and a spraying volume of 0.2L / m². The device is installed at the bottom of the mold car 3 to spray the bottom of the mold car 3 before demolding to reduce friction during demolding and protect the sleeper surface.

[0068] By clarifying these equipment parameters and operating methods, each link in the production process of prefabricated meter-gauge sleepers can be closely coordinated. Accurate mixing and conveying parameters ensure the uniformity of concrete quality, which is beneficial to improving the strength of sleepers. The stable operation of the mold car 3, the accurate positioning of the steel skeleton, and the uniform concrete injection provide a good foundation for subsequent vibration and molding. Appropriate vibration parameters ensure that the concrete is vibrated and compacted, reducing internal defects. The reasonable setting of the hydraulic demoulding device and the automatic lubricant spraying device improves the demoulding efficiency and reduces damage to the sleepers, thereby improving the overall quality and production efficiency of prefabricated meter-gauge sleepers and meeting the quality requirements of the project for sleepers.

[0069] According to another embodiment of the present invention, independent temperature control zones are set along the 4 directions of the curing room track, and thermal insulation curtains are deployed on the top of each zone. The waste heat recovery pipeline is set at the top of the curing room, and the branch end of the pipeline extends to the top of each temperature control zone. The branch pipeline is installed with an electric regulating valve. Different zone control operations are performed according to the core-surface temperature difference, including closing and opening of the thermal insulation curtain, adjusting the opening of the regulating valve, starting the fresh air replacement system, and inserting a transition buffer when the temperature difference between adjacent zones is too large.

[0070] In the maintenance room, independent temperature control zones are set up every 2 meters along the track 4 direction. These zones can be divided by insulation boards installed on the ground and the top. The insulation boards can be made of rock wool, which has good thermal insulation properties and can effectively prevent heat from being transferred between different zones. Insulation curtains are deployed on the top of each zone. The insulation curtains can be made of fireproof and heat-insulating fiberglass materials and installed on the track 4 at the top of the zone. They are opened and closed by motor drive. This setting facilitates fine temperature control of sleepers at different positions and improves the maintenance effect.

[0071] The waste heat recovery pipeline is set at the top of the curing room. It can be made of stainless steel with good corrosion resistance and thermal conductivity. The branch end of the pipeline extends to the top of each temperature control partition, and an electric regulating valve is installed on each branch pipeline. The electric regulating valve can choose a model with remote control function, which is convenient for dynamically adjusting the opening according to the temperature difference of the sleeper core surface in the partition. The electric regulating valve is installed in the branch pipeline near the partition, which can accurately control the amount of waste heat return. The design purpose of the waste heat recovery system is to recover the waste heat in the maintenance process, improve energy utilization and reduce production costs.

[0072] When the core-surface temperature difference is greater than 8°C, the system triggers the closing instruction of the insulation curtain of the corresponding partition, so that the partition forms a semi-enclosed insulation space to reduce heat loss. At the same time, increase the opening of the regulating valve of the waste heat recovery pipeline of the partition to 50%-70%, such as 50%, 60%, and 70%, and return the recovered waste heat to the partition in a directional manner to slow down the cooling speed and avoid cracks in the sleeper due to excessive temperature difference. When the core-surface temperature difference is ≤5°C, open the insulation curtain in stages, first maintain the opening at 30% for 5 minutes and then fully open it, so that the temperature in the partition gradually changes steadily. Close the regulating valve of the waste heat recovery pipeline of the corresponding partition, and start the fresh air replacement system to eliminate the local temperature and humidity gradient. The fresh air replacement system can be composed of a fan and a ventilation duct. The fan is installed on the side wall of the maintenance room, and the ventilation duct is connected to each partition. The introduction and discharge of fresh air is achieved by controlling the operation of the fan. The control data of each partition is mapped to the three-dimensional thermal field simulation interface in real time, and the transition buffer is automatically inserted when the temperature difference between adjacent partitions is greater than 3°C. The transition buffer zone can be achieved by installing a movable insulation curtain. The insulation curtain is made of the same material as the thermal insulation curtain and can be unfolded or retracted as needed to ensure the stability of the temperature field in the maintenance room.

[0073] Through the above implementation, refined temperature control of the cooling zone in the curing room is achieved. The setting of independent temperature control zones and thermal insulation curtains effectively reduces heat loss and heat exchange between different zones. The waste heat recovery system improves energy utilization and reduces production energy consumption. The zoning control operation based on the core-surface temperature difference avoids cracks in the sleepers due to excessive temperature difference, thereby improving product quality. The setting of the three-dimensional thermal field simulation interface and the transition buffer zone further optimizes the temperature field in the curing room, ensures the stability and consistency of the curing process, and enables prefabricated meter-gauge sleepers to obtain better quality assurance during the maintenance stage, meeting the strict requirements of the project for sleeper quality.

[0074] According to another embodiment of the present invention, steam valve opening adjustment when temperature exceeds tolerance: steam valve opening is adjusted according to different amplitudes of positive or negative temperature deviation. Temperature and humidity compensation logic: when temperature and humidity compensation requirements are triggered at the same time, the execution order and related operations are determined. Temperature approaching threshold and abnormal processing: when the temperature approaches the threshold, the steam valve opening is pre-adjusted to handle the situation where continuous adjustment is invalid and the single compensation amplitude is too large.

[0075] In terms of adjusting the opening of the steam valve when the temperature exceeds the tolerance, when the temperature exceeds the tolerance in the positive direction by ΔT> +2℃, the steam valve opening is adjusted in three stages based on the tolerance amplitude. The steam valve can be an electric regulating valve, which is installed on the steam delivery pipeline to control the steam flow and thus adjust the temperature in the curing room. When ΔT≤3℃, the opening is reduced by 1.2% for every 1℃ deviation; for example, if the temperature exceeds the tolerance by 2℃, the steam valve opening is reduced by 2×1.2% = 2.4%. When 3℃<ΔT≤5℃, the opening is reduced by 1.5% for every 1℃ deviation; if the temperature exceeds the tolerance by 4℃, the steam valve opening is reduced by 4×1.5% = 6%. When ΔT>5℃, the emergency shutdown procedure is triggered, the steam supply is cut off and forced heat dissipation is started. The forced heat dissipation device can use an axial flow fan installed on the top or side of the curing room to reduce the indoor temperature by quickly discharging hot air. When the temperature exceeds the tolerance in the negative direction (ΔT< -2℃), the opening degree is increased by 2% for every 1℃ difference, and the increase is accumulated linearly with the duration of the difference. These adjustment ratios are determined through a large number of experiments and data analysis on the relationship between steam flow and temperature changes in the curing room.

[0076] When the temperature and humidity compensation requirements are triggered at the same time, the system automatically executes specific logic. First, the humidity compensation instruction is frozen and stored in the queue to be executed, and temperature compensation is executed first until ΔT returns to the range of ±1.5℃. This is because temperature has a more critical impact on the hydration reaction of concrete. Stabilizing the temperature first can ensure the normal reaction of concrete. Humidity compensation is activated after a delay of 5 minutes, and the compensation amount is associated with the historical data of temperature control. For example, if the opening of the steam valve changes greatly during the previous temperature control process, it means that the indoor heat changes greatly. The spray amount or dehumidification amount can be adjusted accordingly during humidity compensation. The control system determines the compensation demand by receiving data from the temperature and humidity sensors, and issues corresponding instructions to control equipment such as steam valves, spray devices or dehumidification ports. These sensors can use high-precision PT100 temperature sensors and capacitive humidity sensors, which are installed in different positions in the curing room to accurately monitor temperature and humidity.

[0077] When the temperature approaches the threshold of ±1°C, the steam valve opening is pre-adjusted in advance at the ratio of ΔT×0.5% / °C. For example, when the temperature approaches the upper limit and exceeds the tolerance by 0.8°C, the steam valve opening is reduced by 0.8×0.5% = 0.4% in advance to prevent the temperature from exceeding the threshold range. When the temperature has not recovered to the threshold after three consecutive adjustments, the neural network prediction model is triggered to optimize the compensation coefficient. The neural network prediction model is trained based on a large amount of historical temperature and humidity data and adjustment results, and can predict more appropriate adjustment parameters according to the current situation. If the single temperature compensation amplitude exceeds 30% of the total steam valve opening, it is judged as a sensor failure and switched to the standby temperature control mode. The standby temperature control mode can use manual adjustment of the steam valve opening and combine it with manual temperature measurement to ensure that the maintenance process can continue. Through these measures, various complex temperature changes can be effectively dealt with and the maintenance environment can be guaranteed to be stable.

[0078] Through the above-mentioned specific implementation methods, during the steam curing temperature control process, fine adjustments are made for different degrees of temperature deviation to ensure the stability of the temperature in the curing room. Reasonable temperature and humidity compensation logic avoids conflicts in temperature and humidity control, prioritizes temperature stability, and creates good conditions for concrete hydration reactions. The pre-adjustment when the temperature approaches the threshold and the abnormal situation handling mechanism improve the reliability and stability of temperature control, reduce the quality problems of sleepers caused by abnormal temperatures, improve the quality and production efficiency of prefabricated meter-gauge sleepers, and ensure that the production quality of prefabricated meter-gauge sleepers meets engineering requirements.

[0079] According to another embodiment of the present invention, the temperature rise rate deviation value e(t) is calculated in real time, and when |e(t)|>1.5℃ / h, the PID controller control mode is activated. Dynamic parameter adjustment: The proportional coefficient Kp is adjusted in real time according to the deviation, the integral coefficient Ki is adjusted when the cumulative deviation integral reaches the preset threshold, and the differential coefficient Kd is dynamically corrected according to the deviation change rate. Compensation calculation and protection: The steam valve opening compensation ΔV is generated according to the weighted Kp, Ki, and Kd, and a limit protection is applied to ΔV; the control mode is switched when the valve opening is abnormal, and the temperature rate change is monitored after adjustment and the parameter self-tuning program is triggered.

[0080] During the steam curing heating process, the temperature is measured in real time using temperature sensors (such as PT100 temperature sensors) installed in the heating zone. These sensors can be installed near the mold car 3, next to the steam pipe and other key locations to accurately obtain temperature data. By calculating the temperature data at adjacent moments, the temperature rise rate is obtained, and then the temperature rise rate deviation value e(t) is obtained. When |e(t)|>1.5℃ / h, the PID controller control mode is activated. The PID controller can select a general industrial PID controller, which can receive the temperature deviation signal and output the control signal according to the preset algorithm. In practical applications, this 1.5℃ / h threshold is determined by analyzing a large amount of experimental data and temperature fluctuations in the actual production process. Above this threshold, it indicates that the temperature rise rate has a large deviation and needs to be regulated in time.

[0081] During the operation of the PID controller, the proportional coefficient Kp will be adjusted in real time according to the current deviation value. When the deviation is greater than 3℃ / h, Kp is increased to 1.5 times the reference value; when the deviation is less than 1℃ / h, the reference value is restored. For example, if the reference value of Kp is set to 1, when the deviation is 4℃ / h, Kp is adjusted to 1.5. The setting of the reference value is determined by the previous test of the relationship between the steam valve opening and the temperature change. When the accumulated deviation integral reaches the preset threshold (the threshold is determined by multiple tests based on the allowable deviation accumulation in the actual heating process, such as set to 10℃·h), the integral term is automatically reset and the integral coefficient Ki is reduced to 0.8 times to prevent over-adjustment. At the same time, the differential coefficient Kd is dynamically corrected based on the deviation change rate. When the change rate is greater than 0.5℃ / h², Kd is increased to 1.2 times the reference value. For example, if the Kd reference value is 0.5, when the deviation change rate is 0.6℃ / h², Kd is adjusted to 0.6. The dynamic adjustment of these parameters enables the PID controller to control the steam valve opening more accurately according to the actual temperature changes.

[0082] The steam valve opening compensation ΔV is generated according to the weighted Kp, Ki, and Kd. The compensation calculation formula is: ΔV=Kp×e(t)+Ki×∫e(t)dt+Kd×de(t) / dt. The steam valve can be an electric control valve installed on the steam delivery pipeline to receive the signal output by the PID controller to adjust the steam flow. To avoid valve jump, a ±15% limit protection is applied to ΔV. When the valve opening is in the extreme position (>95% or <5%) for 5 minutes and the deviation has not converged, the integral term is frozen and switched to the fuzzy control mode. The fuzzy control mode can be implemented using the existing fuzzy control algorithm module. After each adjustment, the temperature rate change in the next 10 minutes is monitored by the temperature sensor. If the deviation convergence rate is <60%, the PID parameter self-tuning program is automatically triggered to re-optimize the values ​​of Kp, Ki, and Kd. Such a control process can effectively cope with the complex temperature changes during the steam maintenance heating process and ensure a stable temperature rise.

[0083] Through the above implementation, the temperature rise rate can be monitored and controlled in real time and accurately in the steam curing heating zone. When the temperature rise rate deviates, the PID controller responds quickly, and accurately calculates the steam valve opening compensation by dynamically adjusting the proportional, integral and differential coefficients, effectively avoiding excessive temperature fluctuations. Limiting protection and control mode switching under abnormal conditions enhance the stability and reliability of the system. The parameter self-tuning program can automatically optimize the PID parameters according to the actual temperature changes, so that the system can adapt to different working conditions. This series of measures ensures the stability and accuracy of the heating process, reduces the risk of cracks in the sleepers due to thermal stress, improves the quality of prefabricated meter-gauge sleepers, and reasonably controls the maintenance time and improves production efficiency.

[0084] According to another embodiment of the present invention, in the concrete mixing and conveying and injection into the mold, there are clear numerical values, equipment, material selection and assembly requirements. The mixing time can be selected within 3-5 minutes, and the conveying speed of the screw conveyor is determined between 2-5m / s according to the production scale, and is commonly 2m / s, 3m / s, and 4m / s. The screw conveyor is U-shaped, the double-screw mixer 1 is forced, the air pressure valve is a stainless steel pneumatic butterfly valve, the part in contact with concrete is mostly made of wear-resistant alloy steel, the pneumatic butterfly valve body is made of stainless steel, and the seal is made of rubber. The screw conveyor connects the raw material storage area with the double-screw mixer 1, and the discharge port of the double-screw mixer 1 is connected to the buffer hopper 2 through a pipeline, and the air pressure valve controls the flow. When the concrete is injected into the mold, the electromagnetic vibration feeder has a vibration frequency of 50Hz and a vibration amplitude of 2mm, and the mold car 3 runs at a speed of 0.8m / s. The electromagnetic vibration feeder is a standard type, the mold car 3 is made of steel, and the magnetic positioning device can generate a 0.5T magnetic field. The mold cart 3 is made of steel, the shell of the magnetic positioning device is aluminum alloy, and the magnetic core is ferrite magnetic material. The electromagnetic vibration feeder is installed at the bottom of the buffer hopper 2, the mold cart 3 runs on the workshop ground track 4, and the magnetic positioning device is fixed on the inner wall of the mold cart 3.

[0085] Concrete vibration and steam curing are equally critical. The vibrator 5 has an exciting force of 12kN and a vibration frequency of 120Hz. The mold car 3 stays at the vibrating station for 30-50 seconds. The vibrator 5 adopts an eccentric block type, and the supporting vibrating bracket is customized according to the size of the mold car 3. The eccentric block is made of cast iron and the shell is made of cast steel. The two are tightly connected by bolts, and the vibrating bracket is fixed at the vibrating station. In the steam curing stage, the heating rate in the heating zone is 10℃ / h in the first 30 minutes, and then 18℃ / h, with a total heating time of 3.5-4 hours; the humidity preset value in the constant temperature zone is 85%-95%, usually 90%, and the temperature fluctuation is controlled at ±2℃; the core temperature difference threshold in the cooling zone is 8℃ and 5℃, and the cooling rate is 5℃ / h and 10℃ / h. The steam curing room 6 is equipped with a variety of equipment, the wall is made of rock wool board, the steam pipe is a stainless steel pipe, the nozzle of the atomizing spray system is made of stainless steel or engineering plastic, and the negative pressure dehumidification port is made of galvanized steel plate. All equipment is installed as required to jointly ensure maintenance results.

[0086] Finally, it is the hydraulic demoulding process. The hydraulic push device has a single group push force of 8 tons, a push stroke of 200mm, and a push speed of 5mm / s. Standard hydraulic jacks and matching hydraulic pump stations are selected, and an automatic lubricant spraying device is installed at the bottom of the mold car 3. The hydraulic jack cylinder body is made of cast steel, the piston rod is made of high-quality carbon steel, the nozzle of the automatic lubricant spraying device is made of stainless steel, and the liquid storage tank is made of plastic or stainless steel. Four groups of hydraulic push devices are symmetrically installed on both sides of the demoulding station, and contact with the side wall of the mold car 3 through the connecting parts. The hydraulic pump station provides power through the oil pipe. The automatic lubricant spraying device is installed at the bottom of the mold car 3 and sprays before demoulding. Demolding is achieved by four groups of symmetrically arranged hydraulic push devices. The single group push force of the hydraulic push device is 8 tons, the push stroke is 200mm, and the push speed is 5mm / s. When the mold car 3 that has been maintained reaches the hydraulic demoulding station 7, the four groups of hydraulic push devices will start synchronously, and their push ends act on the side wall of the mold car 3. Since the jacking device has sufficient thrust and operates synchronously, it can evenly apply force to the mold car 3. Under the continuous and stable jacking action, the connection between the mold car 3 and the molded sleeper is gradually destroyed, and finally the molded sleeper is separated from the mold car 3 to obtain the demolded sleeper. In addition, the automatic lubricant spraying device set at the bottom of the mold car 3 has a spraying pressure of 0.3MPa and a spraying amount of 0.2L / m². Lubricant will be sprayed on the bottom of the mold car 3 before demolding, which can effectively reduce the friction between the mold car 3 and the sleeper, and assist the hydraulic jacking device to complete the demolding work more smoothly, reducing the risk of damage to the sleeper during the demolding process.

[0087] Although the embodiments of the present invention have been disclosed as above, they are not limited to the applications listed in the specification and the implementation modes, and they can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and the illustrations shown and described herein.

Claims

1. A construction method for an intelligent production line of prefabricated meter-gauge sleepers, characterized in that: The following steps are involved: The concrete raw materials are fed into a double-screw mixer through a screw conveyor. The two screw shafts of the double-screw mixer rotate in opposite directions. The mixing time is 3 to 5 minutes. The mixed concrete flows into a buffer hopper. An electromagnetic vibrating feeder is installed at the bottom of the buffer hopper to evenly inject the mixed concrete into the mold car below; The mold car with concrete injected enters the high-frequency vibrating station through the track. The vibrator adopts an eccentric block vibrator to vibrate the concrete in the mold car. The mold car stays in the vibrating station for 30-50 seconds before moving out. The mold car that has completed the vibration enters the steam curing room, which is divided into a temperature rising zone, a constant temperature zone and a temperature falling zone; The mold cart after curing is transported to the hydraulic demoulding station. The demoulding mechanism includes four sets of symmetrically arranged hydraulic pushing devices. The four sets of hydraulic pushing devices act on the side wall of the mold cart synchronously to separate the molded sleeper from the mold cart to obtain the demoulded sleeper. The temperature rise zone is controlled by segmented gradient, with the temperature rising to 30°C at a rate of 10°C / h in the first 30 minutes, and then rising to 65°C at a rate of 18°C / h. The total heating time is controlled within 3.5-4 hours. A three-level humidity compensation mechanism is set in the constant temperature zone. When the real-time humidity is lower than 85% of the preset value, the atomizing spray system is started. When it is higher than 95% of the preset value, the negative pressure dehumidification port is opened. When the temperature fluctuation exceeds the range of ±2°C, the steam valve opening is automatically adjusted. Dynamic balanced cooling is implemented in the cooling zone. The cooling rate is automatically adjusted according to the temperature difference between the core and the surface of the sleeper. When the temperature difference between the core and the surface is greater than 8°C, the rate is reduced to 5°C / h. When the temperature difference is ≤5°C, the standard rate of 10°C / h is restored.

2. The construction method of the prefabricated meter-gauge sleeper intelligent production line according to claim 1, characterized in that: The specific method of implementing dynamic balanced cooling in the cooling zone includes the following steps: The temperature difference data is collected synchronously by the wireless temperature sensor embedded in the core of the sleeper and the surface contact thermocouple, and uploaded to the central control unit in a cycle of 30 seconds; A simulation model of the temperature field of the sleeper cross section is established. When the real-time value of the core-surface temperature difference ΔT>8°C, it is determined to be a thermal stress risk state. The central control unit sends a speed reduction command to the circulating air system in the cooling area to reduce the cooling rate from 10°C / h to 5°C / h. When the real-time value of the core-surface temperature difference ΔT falls back to the range of 5℃≤ΔT≤8℃, maintain a cooling rate of 5℃ / h; When ΔT≤5℃ and remains stable for 20 minutes, restore the standard cooling rate of 10℃ / h; During the dynamic cooling process, if the coefficient of dispersion of the temperature difference on the core surface of the sleeper of the same maintenance batch exceeds 0.25, an abnormal alarm will be triggered and the mold vehicle will be marked to enter the manual re-inspection queue.

3. The construction method of the prefabricated meter-gauge sleeper intelligent production line according to claim 1 is characterized in that: The specific implementation method of the three-level humidity compensation mechanism in the constant temperature zone includes the following steps: The distributed capacitive humidity sensors and PT100 temperature sensors collect multi-dimensional temperature and humidity data in the constant temperature zone in real time and transmit them to the PID controller at a frequency of 0.1Hz. When the relative humidity is detected to be lower than the preset value of 85%, the pulse modulation mode of the atomizing spray system is started: when the humidity deviation is ≤10%, intermittent spraying is performed at a duty cycle of 30%-50%; when the humidity deviation is greater than 10%, it is switched to continuous spraying and linked to the circulating air system to enhance the uniformity of water mist diffusion; When the relative humidity is detected to be higher than the preset value of 95%, the adaptive regulation of the negative pressure dehumidification port is turned on: Dynamically adjust the opening of the dehumidification port according to the humidity exceeding the standard, the opening ratio K=1.2×(H 实时 -H 目标 ), H is the humidity percentage; Simultaneously reduce the air supply rate of the circulating air system to 60%-80% of the rated value to inhibit moisture diffusion.

4. The construction method of the prefabricated meter-gauge sleeper intelligent production line according to claim 3 is characterized in that: When the temperature fluctuation exceeds the range of ±2℃, dynamic adjustment is performed based on the steam valve opening compensation algorithm: When the temperature exceeds the tolerance in the positive direction, reduce the steam valve opening by the ratio of ΔT×0.8% / ℃; When the temperature exceeds the tolerance in the negative direction, increase the steam valve opening by the ratio of ΔT×1.2% / ℃; If humidity compensation and temperature compensation need to be triggered at the same time, the temperature control instruction is executed first, and the humidity compensation operation is performed after the temperature returns to within the threshold.

5. The construction method of the prefabricated meter-gauge sleeper intelligent production line according to claim 1 is characterized by: The specific implementation method of the temperature rising zone segment gradient control includes the following steps: An infrared temperature scanner is deployed at the entrance of the heating zone to obtain the initial temperature T0 of the mold vehicle surface in real time, and dynamically adjust the subsequent heating rate reference value according to the initial temperature; The steam jet preheating module is activated at startup, and the temperature is raised to 30°C at a constant rate of 10°C / h; When it is detected that the deviation between the actual temperature rise rate and the target rate exceeds ±1.5℃ / h, the steam valve opening is dynamically adjusted through the proportional-integral-differential compound control algorithm, which comprehensively calculates the compensation amount based on the real-time temperature difference deviation value, the accumulated deviation amount and the deviation change rate; When the first stage of heating is completed for 30 minutes, if the measured temperature does not reach 28°C, the first stage of heating time shall be extended until the temperature reaches the standard and the total time shall not exceed 45 minutes; If the measured temperature exceeds 32°C, the subsequent heating rate will be automatically reduced to 15°C / h; A variable rate ramp-up strategy was adopted, with the temperature increasing at a rate of 18°C / h in the initial stage, and the remaining time required for heating up was recalculated every 10 minutes based on the temperature field simulation prediction model; When the total predicted duration will exceed the upper limit of 4 hours, the steam flow rate will be increased step by step according to the ratio of the remaining temperature difference to the remaining time; When the temperature reaches 63°C, switch to the incremental approximation mode and reduce the heating rate to 2°C / h for fine-tuning until the temperature stabilizes within the range of 65°C±0.5°C.

6. The construction method of the prefabricated meter-gauge sleeper intelligent production line according to claim 1 is characterized in that: Also includes: After demoulding, the sleepers are scanned by a visual inspection system, which includes three sets of industrial cameras. The inspection data is transmitted to the central control unit in real time. Among them, three groups of industrial cameras arranged above and on both sides of the sleeper synchronously collect surface images and dimension data, among which: the upper camera detects surface cracks and bubble defects; the cameras on both sides detect the position deviation of the embedded casing; Input the collected data into the AI ​​recognition model to determine in real time whether the following indicators are qualified: If the surface defect area exceeds 0.3%, it will be marked as defective; If the offset of the embedded casing exceeds ±1.5mm, it will be marked as a repaired product; The test results are transmitted to the central control unit in real time. If defective or returned products are found, a defect type report is automatically generated and an audible and visual alarm is triggered. A QR code containing production information is automatically engraved on qualified sleepers, and the test data is encrypted and uploaded to the quality traceability platform.

7. The construction method of the prefabricated meter-gauge sleeper intelligent production line according to claim 1 is characterized in that: The twin-screw mixer conveys concrete at a conveying speed of 3.5 m / s, the screw shaft speed is 25 rpm, and the mixing blade inclination angle is 45°; The mixed concrete flows into the buffer hopper through the control of the air pressure valve; The electromagnetic vibration frequency of the electromagnetic vibration feeder is 50Hz, and the vibration amplitude is 2mm; The mold car intermittently steps on the track at a speed of 0.8m / s. The steel skeleton is pre-set in the mold car and fixed by a magnetic positioning device, which generates a uniform magnetic field of 0.5T. The mold car with concrete injected enters the high-frequency vibrating station through the track. The vibrator adopts an eccentric block vibrator with an exciting force of 12kN and a vibration frequency of 120Hz to vibrate the concrete in the mold car. The mold car stays in the vibrating station for 30-50 seconds before moving out. In the hydraulic jacking device, the jacking force of a single group is 8 tons, the jacking stroke is 200mm, and the jacking speed is 5mm / s; Among them, the bottom of the mold car is also equipped with an automatic lubricant spraying device with a spraying pressure of 0.3MPa and a spraying volume of 0.2L / m².

8. The construction method of the prefabricated meter-gauge sleeper intelligent production line according to claim 1 is characterized by: The implementation method of the dynamic balanced cooling in the cooling zone further includes: Independent temperature control zones are set up every 2 meters along the track direction of the maintenance room, and thermal insulation curtains are deployed on the top of each zone; the waste heat recovery pipeline is set at the top of the maintenance room, and the branch end of the pipeline extends to the top of each temperature control zone. Each branch pipeline is equipped with an electric regulating valve, and the opening of the regulating valve is dynamically associated with the temperature difference of the sleeper core surface of the corresponding zone; When the core temperature difference is greater than 8°C, the following linkage operations are performed: Trigger the closing command of the thermal insulation curtain of the corresponding partition, so that the partition forms a semi-enclosed thermal insulation space; At the same time, increase the opening of the regulating valve of the waste heat recovery pipeline of the zone to 50%-70% to return the recovered waste heat to the zone in a directional manner; when the core-surface temperature difference is ≤5℃, perform the following operations: Open the thermal insulation curtain in stages, first keep it at 30% open for 5 minutes and then open it fully; Close the regulating valve of the waste heat recovery pipeline in the corresponding partition, and start the fresh air replacement system to eliminate the local temperature and humidity gradient; The control data of each partition is mapped to the three-dimensional thermal field simulation interface in real time, and a transition buffer zone is automatically inserted when the temperature difference between adjacent partitions is greater than 3°C.

9. The construction method of the prefabricated meter-gauge sleeper intelligent production line according to claim 4 is characterized by: When the temperature exceeds the positive deviation ΔT>+2℃, the steam valve opening is adjusted in three levels based on the deviation amplitude; When ΔT≤3℃, reduce the opening by 1.2% for every 1℃ excess; When 3℃<ΔT≤5℃, reduce the opening by 1.5% for every 1℃ deviation; When ΔT>5℃, the emergency shutdown procedure is triggered, steam supply is cut off and forced heat dissipation is started; When the temperature exceeds the tolerance in the negative direction (ΔT<-2℃), the opening will be increased by 2% for every 1℃ difference, and the increase will be accumulated linearly with the duration of the difference. In addition, when the temperature and humidity compensation requirements are triggered at the same time, the system automatically executes the following logic: Freeze the humidity compensation instruction and store it in the queue to be executed; Prioritize temperature compensation until ΔT returns to the range of ±1.5℃; Activate humidity compensation after a delay of 5 minutes and associate the compensation amount with the temperature control history data; Furthermore, when the temperature approaches the threshold value of ±1°C, the steam valve opening is pre-adjusted in advance at the ratio of ΔT×0.5% / °C; When the temperature has not returned to the threshold after three consecutive adjustments, the neural network prediction model is triggered to optimize the compensation coefficient; If the single temperature compensation amplitude exceeds 30% of the total opening of the steam valve, it is judged as a sensor failure and switches to the backup temperature control mode.

10. The construction method of the prefabricated meter-gauge sleeper intelligent production line according to claim 5 is characterized by: The dynamic adjustment method of the proportional-integral-differential compound control algorithm includes the following steps: The temperature rise rate deviation value e(t) is calculated in real time. When |e(t)|>1.5℃ / h, the PID controller control mode is activated. The proportional coefficient Kp is adjusted in real time according to the current deviation value. When the deviation is greater than 3℃ / h, Kp is increased to 1.5 times the reference value, and when the deviation is less than 1℃ / h, the reference value is restored; When the accumulated deviation integral reaches the preset threshold, the integral term is automatically reset and the integral coefficient Ki is reduced to 0.8 times to prevent overshoot; Dynamically correct the differential coefficient Kd based on the deviation change rate. When the change rate is greater than 0.5℃ / h², Kd increases to 1.2 times the reference value. The steam valve opening compensation ΔV is generated according to the weighted Kp, Ki, and Kd. The compensation calculation formula is: ΔV=Kp×e(t) + Ki×∫e(t)dt + Kd×de(t) / dt; Apply ±15% limit protection to ΔV to avoid valve jump; When the valve opening is at the limit position (>95% or <5%) for 5 minutes and the deviation has not converged, the integral term is frozen and switched to fuzzy control mode; After each adjustment, the temperature rate change in the subsequent 10 minutes is monitored. If the deviation convergence rate is less than 60%, the PID parameter self-tuning program is automatically triggered.

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