Concrete guardrail prefabrication production line and production process

Abstract

The invention discloses a concrete guardrail prefabrication production line and a production process. The concrete guardrail prefabrication production line comprises a pouring and vibrating system, an integrated mold conveying system, an RGV intelligent warehouse-in and warehouse-out system, a steam curing system, a mold opening and closing system, an automatic hoisting and overturning system, an oil coating system and a centralized control system. The pouring and vibrating system is used for distributing materials and vibrating and compacting concrete materials in the mold box; the RGV intelligent warehouse-in and warehouse-out system is used for warehouse-in and warehouse-out operation of the mold box in the steam curing system; the steam curing system is used for performing steam curing treatment on concrete in the mold box; the mold opening and closing system comprises a mold opening mechanism and a mold closing mechanism, end plates are hinged to the two ends of the mold box, the end plates on the mold box are automatically opened and closed through the mold opening mechanism and the mold closing mechanism, and the mold opening and closing system is matched with the automatic hoisting and overturning system to achieve automatic rapid demolding. According to the invention, automation and intelligence of concrete guardrail preparation are realized; and the opening and closing type mold box is matched with the mold opening and closing system, simple and efficient operation in the demolding process is achieved, and the production efficiency is effectively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of precast concrete components, and particularly to a precast production system and production process for concrete guardrails. Background Art

[0002] With the acceleration of the global urbanization process and the continuous expansion of the transportation network, the demand for concrete guardrails in infrastructure construction such as roads, bridges, and railways has been continuously increasing. As a core component of road safety, the quality, production efficiency, and environmental friendliness of concrete guardrails directly affect the project progress and cost. The traditional on-site casting construction method has gradually been replaced by prefabricated production due to problems such as high pollution, low efficiency, and unstable quality. Prefabricated production can significantly improve the strength, durability, and appearance consistency of guardrails through factory processing and standardized processes, which is in line with the development trend of modern engineering towards green and industrialization.

[0003] However, most existing guardrail prefabrication production lines adopt fixed mold production lines, and processes such as concrete pouring, vibration, and curing are completed by manual or semi-automatic equipment. There are problems such as low automation, difficult mold demoulding and replacement, and limited production capacity. Based on this, developing an efficient and intelligent concrete guardrail prefabrication production line and production process has become a key direction for industrial technology upgrading. Summary of the Invention

[0004] To solve the above technical problems, the present invention provides a precast production system and production process for concrete guardrails. The various processes of guardrail prefabrication are decomposed, and intelligent equipment and standardized processes are used to complete the construction at specific workstations. Each process operates in a flowing water manner according to the set beat time; the operation beat time of each workstation process is basically the same, effectively avoiding waiting time; by setting an end plate opening and closing formwork box and a matching opening and closing mold system, automatic opening and closing of the end plate of the guardrail prefabrication formwork box is realized, thus facilitating the rapid demoulding of the concrete guardrail from the formwork box, saving the formwork box opening and closing time, reducing the labor intensity of demoulding, and improving production efficiency.

[0005] The technical solution adopted by the present invention to solve its technical problems is: a precast production line for concrete guardrails, including a pouring and vibration system, an integrated mold conveying system, an RGV intelligent storage and retrieval system, a steam curing system, an opening and closing mold system, an automatic lifting and flipping system, an oiling system, and a centralized control system; the pouring and vibration system, the RGV intelligent storage and retrieval system, the steam curing system, the opening and closing mold system, the automatic lifting and flipping system, and the oiling system are connected through the integrated mold conveying system, and the centralized control system conducts coordinated regulation of each system;

[0006] Among them, the pouring and vibrating system is composed of a self-propelled lifting batching machine and a composite vibrating table, which is used for batching and vibrating the concrete in the formwork box to make it dense; the RGV intelligent warehousing and outbound system is arranged at both ends of the inlet and outlet of the steam curing system, which is used for the inbound and outbound operations of the formwork box in the steam curing system; the steam curing system is used for steam curing the concrete in the formwork box to accelerate hardening; the mold opening and closing system includes a mold opening mechanism and a mold closing mechanism. The mold opening mechanism and the mold closing mechanism are located at both ends of the formwork box. End plates are hinged and installed at both ends of the formwork box. The end plates on the formwork box are automatically opened and closed by the mold opening mechanism and the mold closing mechanism, and are cooperated with the automatic hoisting and flipping system to realize automatic and rapid demolding; the oil coating system is used for spraying mold release agent in the formwork box before pouring to facilitate subsequent demolding operations.

[0007] Furthermore, the integrated mold conveying system is divided into a horizontal conveying line and a vertical conveying line. A number of workstations are set on both the horizontal conveying line and the vertical conveying line, and front position sensors and rear position sensors are set on each workstation; there are two upper and lower horizontal conveying lines, and the workstations on each horizontal conveying line include a number of ground supporting wheels and friction conveying wheels; the integrated mold conveying system uses a frequency conversion control motor to drive the friction conveying wheels to drive the trolley forward. The trolley automatically decelerates when approaching the target and stops precisely when it senses the sensor.

[0008] Furthermore, the RGV intelligent warehousing and outbound system is composed of two sets of RGV mother and son vehicles. The two sets of RGV mother and son vehicles are arranged at both ends of the inlet and outlet of the curing kiln of the steam curing system. The mother vehicle of the RGV mother and son vehicle runs horizontally along the production line and shuttles under the formwork box trolley; the son vehicle in the RGV mother and son vehicle can lift the formwork box trolley and drive the formwork box trolley to run longitudinally.

[0009] Furthermore, the mold opening mechanism includes a mold opening bracket and an opening and closing lock component and an opening box component arranged on the mold opening bracket; the opening and closing lock component includes an opening and closing seat, a Y-shaped fork and an opening and closing lock oil cylinder. The opening and closing seat is arranged on the mold opening bracket. The cylinder body of the opening and closing lock oil cylinder is hinged on the opening and closing seat. The piston rod of the opening and closing lock oil cylinder is hinged to one end of the Y-shaped fork. The Y-shaped fork is rotatably installed on the opening and closing seat. The end plate of the formwork box is connected to the side plate and the bottom plate of the formwork box through a buckle; the lever of the Y-shaped fork cooperates with the buckle on the formwork box. When the piston rod of the opening and closing lock oil cylinder expands and contracts to drive the Y-shaped fork to rotate, the buckle on the formwork box can be opened or closed; the opening box component is used to drive the opened end plate to turn outward and open.

[0010] Further, the mold opening component includes a mold opening base, a mold opening arm, and a mold opening oil cylinder; the mold opening base is fixed on the mold opening support, the cylinder body of the mold opening oil cylinder is hinged and installed on the mold opening base, the piston rod of the mold opening oil cylinder is hinged to one end of the mold opening arm, the middle part of the mold opening arm is rotatably installed on the mold opening base, a mold opening fixing sleeve is fixed in the middle of the end plate of the mold box. When the piston rod of the mold opening oil cylinder expands and contracts to drive the mold opening arm to rotate, the mold opening arm abuts against the inner side wall of the mold opening fixing sleeve on the end plate, driving the end plate to turn outwards and open.

[0011] Further, the mold clamping mechanism is located between the two legs at the bottom of the mold opening support, and the mold clamping mechanism is located outside the end plate of the mold box. The mold clamping mechanism includes a mold clamping base, a mold clamping pressure arm, and a mold clamping oil cylinder; one end of the mold clamping pressure arm is hinged to the mold clamping base, and then the mold clamping pressure arm can turn around the mold clamping base; one end of the mold clamping oil cylinder is hinged to the mold clamping base, and the other end is hinged to the mold clamping pressure arm. When the piston rod of the mold clamping oil cylinder expands and contracts, it drives the mold clamping pressure arm to rotate, driving the end plate of the mold box to turn towards the closing direction.

[0012] The present invention also provides a precast production process for concrete guardrails. Using the precast production line for concrete guardrails described above, the production process includes the following steps:

[0013] S1: Mold preparation: Prepare the mold box steel mold according to the required guardrail shape;

[0014] S2: Mold pretreatment: Clean the residual concrete in the mold box, and then spray a mold release agent on the inner wall of the mold box;

[0015] S3: Preparation and automatic feeding of the steel bar cage into the mold;

[0016] S4: Concrete preparation and pouring; According to the required material ratio, prepare the concrete and stir it evenly, and then transport and pour it into the mold box prepared in step S;

[0017] S5: Cloth vibration: Pour the concrete into the mold box in layers, and perform high-frequency layered vibration through a vibrating table;

[0018] S6: Surface finishing: Level the concrete surface with a troweling machine;

[0019] S7: Curing: Transport the mold box after S treatment to the curing kiln of the steam curing system for curing;

[0020] S8: Mold opening and closing and demolding and lifting: Transport the mold box after S curing to the mold opening and closing system. After the mold opening and closing system opens the mold box, take out and lift the guardrail component from the mold box through the automatic hoisting and turning system; then, the mold opening and closing system closes the mold box again;

[0021] S9: Repeat steps S2 - S8 until the required production and preparation operations are completed.

[0022] Advantages of the present invention:

[0023] 1. For the precast production line and production process of the concrete guardrail of the present invention, each process of precasting the guardrail is decomposed, and intelligent equipment and standardized processes are used to complete the construction at specific workstations. Each process operates in a flow manner according to the set beat time; the operation beat time of each process at each workstation is basically the same, effectively avoiding waiting time and improving production efficiency.

[0024] 2. By setting an end plate opening and closing mold and a matching mold opening and closing mechanism, the present invention realizes the automatic opening and closing of the end plate of the guardrail precast mold box, thus facilitating the rapid demolding of the concrete guardrail from the mold box, saving the mold box opening and closing time, reducing the labor intensity of demolding, and improving production efficiency. Description of the Drawings

[0025] Figure 1 is the process flow chart of the production process of the present invention.

[0026] Figure 2 is the overall structural schematic diagram of the production line of the present invention.

[0027] Figure 3 is the partial structural schematic diagram of the production line of the present invention.

[0028] Figure 4 is the structural schematic diagram of the pouring and vibrating system in the present invention.

[0029] Figure 5 is the partial structure diagram of the integrated mold conveying system in the present invention.

[0030] Figure 6 is the structural schematic diagram of the RGV mother and son vehicle in the present invention.

[0031] Figure 7 is the principle block diagram of the electric control part of the RGV mother and son vehicle in the present invention.

[0032] Figure 8 is the structural schematic diagram of the mold opening and closing system in the present invention.

[0033] Figure 9 is the side view of the mold opening and closing system in the present invention.

[0034] Figure 10 is the structural schematic diagram for embodying the mold opening mechanism and the mold closing mechanism in the present invention.

[0035] Figure 11 is the overall structural schematic diagram of the mold box in the present invention.

[0036] Figure 12 is the structural schematic diagram of the bottom plate in the present invention.

[0037] Figure 13 It is a schematic structural diagram of the side plate in the present invention.

[0038] Figure 14 It is a schematic structural diagram of the end plate in the present invention.

[0039] Figure 15 It is a schematic structural diagram of the buckle in the present invention.

[0040] Figure 16 It is a schematic structural diagram of the mold clamping mechanism in the present invention.

[0041] In the figure: 1, pouring and vibrating system; 11, self-propelled lifting and distributing machine; 12, composite vibrating table; 2, integrated mold conveying system; 21, ground support wheel; 22, friction conveying wheel; 23, fixed chain plate conveying system; 24, lifting chain plate conveying system; 25, lifting ground support wheel; 26, lifting friction conveying wheel; 27, front position sensor; 28, rear position sensor; 3, RGV mother and son vehicle; 31, mother vehicle; 32, son vehicle; 4, steam curing system; 5, mold opening mechanism; 51, mold opening support; 511, cross beam; 512, leg; 513, beam frame; 514, beam frame lifting oil cylinder; 515, guide post; 52, opening and closing lock component; 521, opening and closing seat; 522, Y-shaped fork; 523, opening and closing lock oil cylinder; 53, case opening component; 531, case opening seat; 532, case opening arm; 533, case opening oil cylinder; 6, mold clamping mechanism; 61, mold clamping base; 62, mold clamping pressure arm; 63, mold clamping oil cylinder; 64, roller; 7, mold box; 71, mold table; 711, base frame; 712, bottom plate fixing frame; 72, bottom plate; 721, bottom plate body; 722, bottom plate skeleton; 723, end plate fixing part; 724, end plate guide sleeve I; 73, end plate; 731, end plate body; 732, end plate skeleton; 733, hinge pin shaft; 734, guide shaft; 735, mold opening fixing sleeve; 74, side plate; 741, side plate body; 742, side plate skeleton; 743, guardrail forklift groove forming block; 744, end plate guide sleeve II; 75, buckle fixing shaft; 76, buckle; 761, buckle plate; 762, fixed rotating shaft; 763, buckle compression spring; 764, locking tension spring. Detailed implementation manners

[0042] Now, the present invention will be further described in detail with reference to the accompanying drawings. These drawings are all simplified schematic diagrams, only illustrating the basic structure of the present invention in a schematic manner, so they only show the components related to the present invention.

[0043] The present invention discloses a precast production line for concrete guardrails.

[0044] Refer to Figure 1 and Figure 2, a precast production line for concrete guardrails includes a pouring and vibrating system 1, an integrated mold conveying system 2, an RGV intelligent warehousing system, a steam curing system 4, a mold opening and closing system, an automatic hoisting and flipping system, an oiling system, and a centralized control system; the pouring and vibrating system 1, the RGV intelligent warehousing system, the steam curing system 4, the mold opening and closing system, the automatic hoisting and flipping system, and the oiling system are connected through the integrated mold conveying system 2, and the centralized control system coordinates and controls each system.

[0045] Refer to Figure 3 and Figure 4 , the pouring and vibrating system 1 adopts the pouring and vibrating integrated forming technology, which is composed of a self-propelled lifting batching machine 11 and a composite vibrating table 12. The concrete raw materials are delivered by a tank truck. After being delivered to the designated position, the self-propelled lifting batching machine 11 descends to the ground for material receiving. After completing the material receiving, it rises above the working surface and then automatically travels to the pouring station for pouring. During the pouring process, the self-propelled lifting batching machine 11 is linked with the composite vibrating table 12 according to the required batching amount to vibrate and compact. The self-propelled lifting batching machine 11 adopts multi-gate pouring control to achieve rapid batching. Each gate can be opened and closed independently, which is convenient for replenishment control; the pouring and vibrating system 1 adopts high-frequency stratified vibration, with fast forming speed, high quality, and dense internal structure.

[0046] The self-propelled lifting batching machine 11 adopts variable-frequency control to move in three-dimensional X, Y, and Z directions, and is equipped with an encoder and proximity switches to accurately locate the material taking point and batching point. During use, software and hardware measures such as transmitting the encoder value and the signal of the over-position sensor to the central control unit and using physical stoppers are adopted to protect the equipment safety during the mechanical stroke. During pouring, the composite vibrating table 12 adopts variable-frequency vibration to achieve multi-layer compaction.

[0047] Refer to Figure 2 and Figure 5 , the integrated mold conveying system 2 includes a mold trolley, ground support wheels 21 and friction conveying wheels 22, a fixed chain plate conveying system 23, a lifting chain plate conveying system 24, lifting ground support wheels 25 and lifting friction conveying wheels 26; the integrated mold conveying system 2 is divided into a horizontal conveying line (X direction) and a vertical conveying line (Y direction). A number of workstations are set on each conveying line.

[0048] Among them, there are two upper and lower horizontal conveying lines. Each workstation on the horizontal conveying line includes six ground support wheels 21 and two friction conveying wheels 22; the number of workstations on the horizontal conveying line is 5 + N; N is the number of columns of the curing kiln. Generally, 6 - 10 columns of curing kilns are set; each column of curing kiln can cure 6 - 10 pieces of guardrails. Each workstation can achieve linkage and single-action control. Each workstation is equipped with a front position sensor 27 and a rear position sensor 28. The friction drive is all variable-frequency drive, and the essence group position docking is realized in cooperation with the sensor.

[0049] The longitudinal conveyor line includes a lifting chain plate conveyor system 24, a fixed chain plate conveyor system 23, lifting ground support wheels 25 and lifting friction conveyor wheels 26. The length of the fixed chain plate conveyor system 23 is determined according to the length of each row of curing kilns, that is, the number of guardrails to be cured. Position sensors are arranged on each working station arranged longitudinally to achieve lateral position ferry control. Thus, the die trolley realizes automatic circulation in the vertical and horizontal directions. This integrated die conveying system 2 uses a frequency conversion control motor to drive the friction conveyor wheel 22 to drive the trolley forward. The trolley automatically decelerates when approaching the target and stops precisely when it senses the sensor.

[0050] Refer to Figure 6 and Figure 7 As shown in

[0051] In the electrical structure of the RGV mother - son vehicle 3, the mother vehicle 31 is driven forward by a frequency conversion control motor. The mother vehicle 31 automatically decelerates when approaching the target and stops precisely when it senses the sensor. The two son vehicles 32 use hydraulic lifting to jack up the component, and the servo drives the son vehicle 32 to drive the component forward, and precise positioning is achieved by using a dual - encoder of a servo encoder and a pressure wheel encoder. In the communication structure, a central controller of the mother vehicle 31 and the two son vehicles 32 exchanges data such as synchronization, position, command, and alarm through wireless communication. After the RGV twin vehicle 32 sends the component to the target position, the system records the position state of the component.

[0052] Refer to Figure 2 As shown in

[0053] The curing kiln can be cured separately for each column and is divided into two curing methods: manual and automatic. Manual method: After detecting that the kiln door is closed, manually set the temperature and duration of the corresponding column for automatic curing. Automatic method: After the system detects that this column of components is full, it automatically cures according to the set temperature and duration. Temperature control uses a temperature sensor to collect the temperature inside the kiln to the central control unit, and sets the heating-up duration, heating-up interval, constant-temperature duration, cooling-down duration, cooling-down interval, and over-temperature protection according to the requirements of the components. The heating and cooling are respectively controlled by the central control unit to adjust the opening interval of the steam solenoid valve and the opening interval of the spray water solenoid valve.

[0054] Refer to Figures 8 to 10 , the mold opening and closing system includes a mold opening mechanism 5, a mold closing mechanism 6, a hydraulic station, and an electric control system. The hydraulic station is used to provide power for the hydraulic cylinders of the mold opening mechanism 5 and the mold closing mechanism 6, and the movement is regulated through the electric control system. The mold opening mechanism 5 and the mold closing mechanism 6 are located at both ends of the mold box 7. End plates 73 are hinged at both ends of the mold box 7. The end plates 73 on the mold box 7 can be automatically and quickly opened and closed by the mold opening mechanism 5 and the mold closing mechanism 6, which facilitates the rapid demolding of the concrete guardrail from the mold box 7, saves the opening and closing time of the mold box 7, reduces the labor intensity, and improves the labor efficiency.

[0055] Refer to Figure 11 , the mold box 7 includes a mold table 71, a bottom plate 72, side plates 74, end plates 73, and fasteners 76; among them, the bottom plate 72 is fixed on the mold table 71, the side plates 74 are installed on one side of the bottom plate 72 assembly, the end plates 73 are hinged and installed at both ends of the bottom plate 72 through pins, and the end plates 73 are connected to the side plates 74 and the bottom plate 72 through the fasteners 76. The mold box 7 is placed on a vibrating table through the mold table 71 to vibrate the concrete, ensuring that the guardrail is poured and formed tightly. The fasteners 76 can be quickly opened in cooperation with the mold opening and closing system to achieve the rapid separation between the precast concrete guardrail and the bottom plate 72, side plates 74, and end plates 73, saving the separation time between the solidified guardrail and the mold box 7, reducing the demolding labor intensity, and improving the labor efficiency.

[0056] Refer to Figure 11 , the mold table 71 includes a base frame 711 and a bottom plate fixing frame 712. The base frame 711 is a square frame formed by welding several channel steels arranged vertically and horizontally. The bottom plate fixing frame 712 is welded and fixed on the base frame 711 for supporting and fixing the bottom plate 72 assembly. Several groups of bottom plate fixing frames 712 are arranged along the length direction of the base frame 711. The bottom plate fixing frame 712 is composed of several fixing pillars, and the heights of the several fixing pillars increase along the width direction of the base frame 711 to adapt to the bottom contour of the bottom plate 72 assembly.

[0057] Refer to Figure 12, the bottom plate 72 includes a bottom plate body 721, a bottom plate skeleton 722, an end plate fixing member 723, and an end plate guide sleeve I 724; the bottom plate skeleton 722 is formed by vertically and cross-welding a plurality of cross bars and longitudinal bars, and the bottom plate skeleton 722 is welded and fixed to the side wall of the bottom plate body 721 close to the mold table 71, and the bottom plate fixing frame 712 is connected to the bottom plate skeleton 722. The end plate fixing member 723 is arranged at both ends in the length direction of the bottom plate 72. The end plate fixing member 723 includes a rib plate and a connecting plate. The connecting plate is welded and fixed to the end of the bottom plate 72 and is located on the side of the bottom plate 72 close to the mold table 71, and the rib plate is welded and fixed between the bottom plate 72 and the connecting plate. The end plate guide sleeve I 724 is located at one end of the connecting plate and is inserted and fixed in the connecting plate.

[0058] Refer to Figure 13 , the side plate 74 is fixed to the bottom plate 72 by bolts. The side plate 74 includes a side plate body 741, a side plate skeleton 742, a guardrail forklift slot forming block 743, and an end plate guide sleeve II 744; the side plate skeleton 742 is formed by vertically and cross-welding cross bars and longitudinal bars, and the side plate skeleton 742 is welded and fixed to the outer side wall of the side plate 74 away from the bottom plate 72; the end plate guide sleeve II 744 is fixedly installed at both ends in the length direction of the side plate 74, and the end plate guide sleeve I 724 on the bottom plate 72 cooperates with the end plate guide sleeve II 744 of the side plate 74 to realize the guiding of the closing of the end plate 73.

[0059] There are two guardrail forklift slot forming blocks 743, and the two guardrail forklift slot forming blocks 743 are fixed to the side wall of the side plate body 741 away from the side plate skeleton 742, so that the cast guardrail has forklift slots, which is convenient for the subsequent handling and transportation of the guardrail precast members.

[0060] Refer to Figure 14 and Figure 15, the end plate 73 includes an end plate body 731, an end plate skeleton 732, a hinge pin 733, a guide shaft 734, a buckle fixing shaft 75, and a mold opening fixing sleeve 735; the end plate skeleton 732 is welded and fixed to one side wall of the end plate body 731, the hinge pin 733 is arranged at the bottom of the end plate 73, the end plate 73 is hinged to the bottom plate 72 through the hinge pin 733, the mold opening fixing sleeve 735 is a hollow square tube, and the mold opening fixing sleeve 735 is fixed to the middle of the end plate skeleton 732. There are two guide shafts 734, and the two guide shafts 734 are welded and fixed to the inner side wall of the end plate 73. The two guide shafts 734 are matched with the end plate guide sleeve I 724 and the end plate guide sleeve II 744, and then the closing guide of the end plate 73 is realized through the guide shafts 734; the buckle fixing shafts 75 are welded and fixed to both ends of the end plate 73, and are matched with the buckles 76 to realize the fixation of the end plate 73. The buckle 76 includes a buckle plate 761, a fixed rotating shaft 762, a buckle compression spring 763, and a locking tension spring 764. The fixed rotating shaft 762 is installed on the outer side wall of the side plate 74 or the bottom plate 72. One ends of the buckle compression spring 763 and the locking tension spring 764 are connected to the buckle plate 761, and the other ends are connected to the side plate 74 or the bottom plate 72 to provide a tension force to ensure the stability during the snap locking; the buckle plate 761 rotates around the fixed rotating shaft 762 to realize the clamping and separation from the buckle fixing shaft 75 on the end plate 73.

[0061] Referring to the figures, the mold opening mechanism 5 includes a mold opening bracket 51, a opening and closing lock component 52, and an unpacking component 53; the mold opening bracket 51 includes a cross beam 511 and legs 512 vertically fixed to the bottoms of both ends of the cross beam 511; a beam frame 513 is arranged below the cross beam 511, a beam frame 513 lifting oil cylinder is fixed on the cross beam 511, and the piston rod of the beam frame 513 lifting oil cylinder is fixedly connected to the beam frame 513, and then the beam frame 513 can be driven to move up and down. And in order to ensure the smoothness of the up and down movement of the beam frame 513, guide columns 515 are fixed at both ends of the beam frame 513, and the ends of the guide columns 515 away from the beam frame 513 are slidably inserted into the cross beam 511, and then the guide columns 515 play a guiding role in the up and down movement of the beam frame 513.

[0062] Referring to the figures, there are two opening and closing lock components 52, which are respectively installed at both ends of the beam frame 513. The opening and closing lock component 52 includes an opening and closing seat 521, a Y-shaped fork 522 and an opening and closing lock oil cylinder 523. The opening and closing seat 521 is fixed on the beam frame 513. The cylinder block of the opening and closing lock oil cylinder 523 is hinged on the opening and closing seat 521. The piston rod of the opening and closing lock oil cylinder 523 is hinged to one end of the Y-shaped fork 522. The Y-shaped fork 522 is located at the bottom of the opening and closing lock oil cylinder 523 and is rotatably installed on the opening and closing seat 521 through a pin shaft. The lever of the Y-shaped fork 522 cooperates with the buckle plate 761 of the buckle 76. When the piston rod of the opening and closing lock oil cylinder 523 expands and contracts, it can drive the Y-shaped fork 522 to rotate, and then the buckle plate 761 is lifted, so that the end plate 73 of the mold box 7 is disengaged from the connection with the side plate 74 and the bottom plate 72 and can be turned outward.

[0063] Referring to Figure 10 , the mold opening component 53 includes a mold opening seat 531, a mold opening arm 532 and a mold opening oil cylinder 533; the mold opening seat 531 is fixed in the middle of the beam frame 513. The cylinder block of the mold opening oil cylinder 533 is hinged on the mold opening seat 531. The piston rod of the mold opening oil cylinder 533 is hinged to one end of the mold opening arm 532. The mold opening arm 532 is located at the bottom of the mold opening oil cylinder 533. The middle of the mold opening arm 532 is rotatably installed on the mold opening seat 531 through a pin shaft. Then when the piston rod of the mold opening oil cylinder 533 expands and contracts, it can drive the mold opening arm 532 to rotate. When the opening and closing lock component 52 of the mold opening mechanism 5 pries up the buckle plate 761 of the buckle 76 and makes the end plate 73 in a rotatable active state, at this time, the piston rod of the mold opening oil cylinder 533 extends, driving the mold opening arm 532 to turn over, so that the mold opening arm 532 abuts against the inner side wall of the mold opening fixing sleeve 735 on the end plate 73, and the end plate 73 of the mold box 7 is turned outward and opened.

[0064] Referring to Figure 16 , the mold closing mechanism 6 is located between the two legs 512 at the bottom of the mold opening bracket 51; the mold closing mechanism 6 includes a mold closing base 61, a mold closing pressure arm 62 and a mold closing oil cylinder 63. One end of the mold closing pressure arm 62 is hinged to the mold closing base 61 through a pin shaft, and then the mold closing pressure arm 62 can be turned over around the mold closing base 61. One end of the mold closing oil cylinder 63 is hinged to the mold closing base 61, and the other end is hinged to the mold closing pressure arm 62. When the piston rod of the mold closing oil cylinder 63 expands and contracts, it can drive the mold closing pressure arm 62 to rotate.

[0065] When the mold closing mechanism 6 is in use, it is located outside the end plate 73 of the mold box 7. When the end plate 73 is turned over and opened, the outer side wall of the end plate 73 presses on the mold closing pressure arm 62; if mold closing operation is required, the mold closing oil cylinder 63 extends, driving the mold closing pressure arm 62 to turn over towards the direction close to the mold box 7. Then the mold closing pressure arm 62 drives the end plate 73 to turn over towards the closing direction; after that, the opening and closing lock component 52 of the mold opening mechanism 5 is activated, and the buckle 76 is driven by the Y-shaped fork 522 to be buckled again to complete the mold closing operation.

[0066] A roller 64 is rotatably installed at one end of the mold - clamping pressure arm 62 away from the end connected to the mold - clamping base 61. A rubber ring is coated on the outer periphery of the roller 64. When the mold - clamping pressure arm 62 drives the end plate 73 to close and flip, the mold - clamping pressure arm 62 is in flexible contact with the outer side wall of the end plate 73 through the roller 64, reducing the frictional force between the mold - clamping pressure arm 62 and the end plate 73 and preventing scratches on the outer wall of the end plate 73, playing a protective role.

[0067] Referring to Figure 1 and Figure 2 The automatic lifting and flipping system consists of a vacuum system, a lifting system, a flipping system, a walking system, and a frame. After the mold - opening and closing system completes the mold - opening of the mold box trolley, the automatic lifting and flipping system adsorbs and removes the formed guardrail from the mold box 7, performs a 90 - degree flip, and walks while flipping to the placement station for placement. In this way, the demolding and lifting of the component are completed.

[0068] The vacuum pump is directly started, and an isolation relay is used to control the reversing solenoid valve to adsorb the mold. The lifting and walking mechanisms use variable - frequency control for acceleration and deceleration to smoothly move the lifting and walking structures, and are combined with an encoder and proximity switches for precise positioning.

[0069] The oil - coating system works based on the principle of a two - fluid atomizing nozzle. It includes a high - pressure pneumatic system, a release agent pumping system, an array nozzle swing system, and an equipment frame. After the aforementioned automatic lifting and flipping system completes its work, after the mold box 7 is cleaned, it is transported through the aforementioned integrated mold conveying system 2. The mold box trolley arrives at the oil - coating station, and the oil - coating system starts to operate to perform the full - cross - section spraying of the release agent. After the work is completed, it is transported to the next station through the aforementioned integrated mold conveying system 2 for the steel bar cage to be put into the mold. After the steel bar cage is put into the mold, the fixed chain - plate conveying system 23 and the lifting chain - plate conveying system 24 in the integrated mold conveying system 2 transport the mold box trolley to the pouring and vibrating station for pouring and vibrating to form the product.

[0070] The centralized control system includes a monitoring system, a display system, a production line control system, and a central control room. Each of the aforementioned systems can operate independently or be jointly controlled in the centralized control system. Using a digital twin system, the centralized control system can make the entire production line automatically flow according to a rhythm of 6 minutes per beat. The overall production is carried out according to the established production plan, and the operating status of each station in the middle can be dynamically displayed in the centralized control system. Each device in the pouring and vibrating system 1, the integrated mold conveying system 2, the RGV intelligent storage and retrieval system, the steam curing system 4, the mold - opening and closing system, the automatic lifting and flipping system, and the oil - coating system exchanges data of its own information with the central control room server through the TCP / IP protocol. The server uses C# programming and digital twin applications to display the operating status of each single machine, alarm information, etc. on the screen, presenting the operating conditions of the equipment.

[0071] The present invention also discloses a precast production process for concrete guardrails. The process includes the following steps:

[0072] S1: Mold preparation: Prepare the steel mold of the mold box 7 according to the required shape of the guardrail;

[0073] S2: Mold pretreatment: Use a high-pressure water gun to wash the residual concrete in the mold box 7, and then spray a water-based release agent or a special oil-based agent (such as silicone resin) on the inner wall of the mold box 7, with a dosage of 0.1-0.2 kg / m 2 , ensuring uniform coverage;

[0074] S3: Preparation and automatic insertion of the steel bar cage: Use CRB550 cold-rolled ribbed steel bars with a diameter of 8-12 mm. After cutting according to the drawings, spot-weld them into a mesh sheet and install the required embedded parts to prepare a steel bar cage; Subsequently, automatically lift and transport the steel bar cage into the mold box 7;

[0075] S4: Concrete preparation and pouring: After mixing sand, stones, cement, water, and additives according to the required ratio to prepare concrete and stirring it evenly, transport and pour it into the mold box 7 prepared in S3;

[0076] S5: Cloth and vibrate: Pour the concrete into the mold box 7 in layers and vibrate it in high-frequency layers through a vibrating table;

[0077] S6: Surface finishing: Level the concrete surface with a troweling machine;

[0078] S7: Curing: Transport the mold box 7 processed in S6 to the curing kiln of the steam curing system 4 for curing; During the heating-up stage, the heating rate ≤ 15 °C / h until the temperature reaches 55-60 °C; During the constant-temperature stage, maintain the temperature at 55-60 °C and the humidity ≥ 90% for 12-15 h; During the cooling-down stage, the cooling rate ≤ 10 °C / h until it drops to room temperature;

[0079] S8: Mold opening and closing and demolding and lifting: Transport the mold box 7 cured in S7 to the mold opening and closing system. After the mold box 7 is opened by the mold opening and closing, take out and lift the guardrail component from the mold box 7 through the automatic lifting and flipping system; After that, the mold opening and closing system closes the mold box 7 again;

[0080] S9: Repeat steps S2-S8 until the required production and preparation operations are completed.

[0081] Inspired by the ideal embodiments of the present invention described above, through the above description, relevant staff can completely make various changes and modifications without departing from the technical idea of the present invention. The technical scope of the present invention is not limited to the content in the specification, and its technical scope must be determined according to the scope of the claims.

Claims

1. A concrete guardrail prefabrication production line, characterized by: The invention comprises a pouring and vibrating system (1), an integrated mold conveying system (2), an RGV intelligent in-and-out storage system, a steam curing system (4), a mold opening and closing system, an automatic hoisting and turning system, an oiling system and a centralized control system; the pouring and vibrating system (1), the RGV intelligent in-and-out storage system, the steam curing system (4), the mold opening and closing system, the automatic hoisting and turning system, and the oiling system are connected via the integrated mold conveying system (2), and the centralized control system performs coordinated regulation of the various systems; The pouring and vibrating system (1) is composed of a self-propelled lifting material distributor (11) and a composite vibration table (12), and is used for distributing materials and vibrating and compacting the concrete material in the mold box (7); the RGV intelligent in-and-out storage system is arranged at both ends of the inlet and outlet of the steam curing system (4), and is used for the in-and-out storage operation of the mold box (7) in the steam curing system (4); the steam curing system (4) is used for steam curing the concrete in the mold box (7) to accelerate hardening; the mold opening and closing system comprises a mold opening mechanism (5) and a mold closing mechanism (6), the mold opening mechanism (5) and the mold closing mechanism (6) are located at both ends of the mold box (7), and the two ends of the mold box (7) are hingedly mounted with end plates (73), and the end plates (73) on the mold box (7) are automatically opened and closed by the mold opening mechanism (5) and the mold closing mechanism (6), and automatic rapid demoulding is realized in cooperation with the automatic lifting and flipping system; the oiling system is used for spraying a demoulding agent in the mold box (7) before pouring, so as to facilitate subsequent demoulding operations.

2. The concrete guardrail prefabrication production line according to claim 1 is characterized by: The integrated mold conveying system (2) is divided into a transverse conveying line and a longitudinal conveying line. A plurality of workstations are arranged on the transverse conveying line and the longitudinal conveying line. Each workstation is provided with a front position sensor (27) and a rear position sensor (28). The transverse conveying line is provided with two upper and lower lines. Each workstation on the transverse conveying line includes a plurality of ground support wheels (21) and friction conveying wheels (22). The integrated mold conveying system (2) uses a variable frequency controlled motor to drive the friction conveying wheels (22) to drive the trolley forward. The trolley automatically decelerates when approaching a target and stops precisely when sensing a sensor.

3. The concrete guardrail prefabrication production line according to claim 1 is characterized in that: The RGV intelligent in-and-out storage system is composed of two sets of RGV mother-and-child vehicles (3). The two sets of the RGV mother-and-child vehicles (3) are arranged at both ends of the inlet and outlet of the curing kiln of the steaming system (4). The mother vehicle (31) of the RGV mother-and-child vehicles (3) runs horizontally along the production line and shuttles under the mold box trolley; the sub-vehicle (32) in the RGV mother-and-child vehicles (3) can lift the mold box trolley and drive the mold box trolley to run longitudinally.

4. A concrete guardrail prefabrication production line according to any one of claims 1 to 3, characterized in that: The mold opening mechanism (5) comprises a mold opening bracket (51), an opening and closing lock component (52) and a box opening component (53) arranged on the mold opening bracket (51); the opening and closing lock component (52) comprises an opening and closing seat (521), a Y-shaped shift fork (522) and an opening and closing lock oil cylinder (523); the opening and closing seat (521) is arranged on the mold opening bracket (51); the cylinder body of the opening and closing lock oil cylinder (523) is hinged on the opening and closing seat (521); the piston rod of the opening and closing lock oil cylinder (523) is hinged to one end of the Y-shaped shift fork (522); the Y-shaped shift fork (522) is hinged to the cylinder body of the opening and closing lock oil cylinder (523); The shift fork (522) is rotatably mounted on the opening and closing seat (521); the end plate (73) of the mold box (7) is connected to the side plate (74) and the bottom plate (72) of the mold box (7) through a buckle (76); the shift rod of the Y-shaped shift fork (522) cooperates with the buckle (76) on the mold box (7); when the piston rod of the opening and closing lock oil cylinder (523) is telescopically driven to rotate the Y-shaped shift fork (522), the buckle (76) on the mold box (7) can be opened or closed; the opening component (53) is used to drive the unlocked end plate (73) to flip outward and open.

5. The concrete guardrail prefabrication production line according to claim 4 is characterized by: The box opening component (53) comprises a box opening seat (531), a box opening arm (532) and a box opening oil cylinder (533); the box opening seat (531) is fixed on the mold opening bracket (51); the cylinder body of the box opening oil cylinder (533) is hingedly mounted on the box opening seat (531); the piston rod of the box opening oil cylinder (533) is hingedly mounted on one end of the box opening arm (532); the middle part of the box opening arm (532) is rotatably mounted on the box opening seat (531); a mold opening fixing sleeve (735) is fixed to the middle part of the end plate (73) of the mold box (7); when the piston rod of the box opening oil cylinder (533) is extended and retracted to drive the box opening arm (532) to rotate, the box opening arm (532) contacts the inner side wall of the mold opening fixing sleeve (735) on the end plate (73), driving the end plate (73) to flip outward and open.

6. The concrete guardrail prefabrication production line according to claim 5 is characterized by: The mold clamping mechanism (6) is located between the two legs (512) at the bottom of the mold opening bracket (51), and the mold clamping mechanism (6) is located outside the end plate (73) of the mold box (7). The mold clamping mechanism (6) includes a mold clamping base (61), a mold clamping pressure arm (62) and a mold clamping oil cylinder (63); one end of the mold clamping pressure arm (62) is hinged on the mold clamping base (61), and then the mold clamping pressure arm (62) can be turned around the mold clamping base (61); one end of the mold clamping oil cylinder (63) is hinged to the mold clamping base (61), and the other end is hinged to the mold clamping pressure arm (62), and when the piston rod of the mold clamping oil cylinder (63) is extended and retracted, the mold clamping pressure arm (62) is driven to rotate, thereby driving the end plate (73) of the mold box (7) to turn toward the closing direction.

7. A concrete guardrail prefabrication production process, characterized in that: The concrete guardrail prefabrication production line according to claim 6 is adopted, and the production process comprises the following steps: S1: Mould preparation: prepare a mould box (7) steel mould according to the required guardrail shape; S2: Mould pretreatment: cleaning the residual concrete in the mould box (7), and then spraying a mould release agent on the inner wall of the mould box (7); S3: Preparation of steel mesh cage and automatic mold insertion; S4: concrete preparation and pouring: after preparing the concrete according to the required material ratio and mixing it evenly, it is then transported and poured into the mold box (7) prepared in step S3; S5: concrete distribution and vibration: concrete is poured and distributed in layers into the mold box (7), and high-frequency layered vibration is performed through a vibration table; S6: Surface finishing: Smooth the concrete surface by troweling machine; S7: Curing: transporting the mold box (7) treated in S6 to a curing kiln of the steam curing system (4) for curing; S8: mold opening and closing and demoulding and lifting: the mold box (7) after curing in S7 is transported to the mold opening and closing system. After the mold box (7) is opened by the mold opening and closing system, the guardrail component is taken out of the mold box (7) and lifted away by the automatic lifting and flipping system; thereafter, the mold opening and closing system closes the mold box (7) again; S9: Repeat steps S2-S8 until the required production preparation operations are completed.

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