Die device for prestressed concrete sleeper and sleeper forming method

Abstract

The invention provides a mold device for a prestressed concrete sleeper and a sleeper forming method, and belongs to the technical field of sleeper production equipment. According to the technical scheme, the mold device for the prestressed concrete sleeper comprises prestressed steel wires and further comprises a plate distribution frame, a plurality of partition plates and a mold shell, the mold shell extends in the first direction, the plate distribution frame is provided with a partition plate storage space, and the partition plates are stored in the partition plate storage space in the first direction; the prestressed steel wires sequentially penetrate through the partition plates, the plate distribution frame is connected with a driving mechanism to drive the plate distribution frame to move in the first direction, the partition plate releasing mechanism releases the partition plates at intervals in the first direction, and the partition plates divide the forming bin into a plurality of sleeper forming spaces. The multiple partition plate pieces are stacked in the partition plate storage space in the first direction, the prestressed steel wire sequentially penetrates through the multiple partition plate pieces, the penetrating length of the prestressed steel wire is reduced, the prestressed steel wire penetrating efficiency is improved, and the sleeper forming efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of sleeper production equipment, and in particular to a die device for prestressed concrete sleepers and a sleeper forming method. Background Art

[0002] Prestressed concrete sleepers are important components of railway tracks and are widely used in high-speed railways, urban rail transit, and ordinary railways. The sleepers reinforced by prestress technology can withstand greater loads and deformations, improve the overall stability of the track structure, and contribute to enhancing the safety and smoothness of train operation. In addition, with the precast process and factory production, the workload at the construction site is reduced, the construction period is greatly shortened, the service life of prestressed concrete sleepers is long, the maintenance frequency is reduced, and the maintenance cost is lowered.

[0003] In the production of prestressed concrete sleepers, in order to improve production efficiency, the long-line method is usually used. The sleeper dies are distributed in one direction, and the non-prestressed steel wires are sequentially passed through multiple sleeper dies. Then, prestress is applied to the steel wires to make them taut, and then concrete is poured into the sleeper dies to complete the production of sleepers. However, in this production method, manual operation is usually used to sequentially pass the steel wires through multiple placed sleeper dies. Since the length of the sleeper die is long and includes multiple partitions during long-line production, the alignment speed of sequentially passing the steel wires is slow, and the efficiency of passing the steel wires is low. Therefore, the production efficiency of sleepers is low, and a large amount of manpower is consumed, increasing the production cost. Summary of the Invention

[0004] Aiming at the problems that during the production of prestressed sleepers by the long-line method, manual threading of steel wires into the sleeper dies in sequence usually results in low production efficiency and high production cost, the present invention provides a die device for prestressed concrete sleepers and a sleeper forming method.

[0005] To achieve the above object, the present invention adopts the following technical solutions:

[0006] The present invention provides a die device for prestressed concrete sleepers, including prestressed steel wires, and further including a cloth board frame, a plurality of partition members, and a die housing. The die housing extends along a first direction, and the die housing is provided with a forming chamber opening to one side. The cloth board frame is arranged on the side opposite to the forming chamber, and the cloth board frame is provided with a partition storage space. The plurality of partition members are stored in the partition storage space along the first direction. The partition members are provided with a plurality of through holes, and the prestressed steel wires pass through the plurality of partition members in sequence through the through holes. The partition storage space is provided with a partition release mechanism, and the partition release mechanism is at least used to place the partition members from the partition storage space into the forming chamber. The cloth board frame is connected with a driving mechanism, and the driving mechanism is at least used to drive the cloth board frame to move along the first direction, so that the partition release mechanism releases the partition members at intervals along the first direction. The plurality of partition members divide the forming chamber into a plurality of sleeper forming spaces.

[0007] Further, the cloth board frame includes an upper frame body and a lower frame body which are arranged relatively and spaced apart. One end of the upper frame body along the first direction and one end of the lower frame body along the first direction are connected with a plurality of vertical beams. The other ends of the upper frame body and the lower frame body form an opening for the partition members to pass through. The upper frame body, the lower frame body and the plurality of vertical beams enclose a storage space.

[0008] Further, the upper frame body includes a plurality of first hole groups evenly spaced along the first direction. Each first hole group includes a plurality of first locking holes evenly spaced along a direction perpendicular to the first direction. The lower frame body includes a plurality of second hole groups evenly spaced along the first direction. Each second hole group includes a plurality of second locking holes evenly spaced along a direction perpendicular to the first direction. And the first locking holes and the second locking holes are arranged oppositely. The partition release mechanism includes a locking component. The locking component includes a locking pin body. The locking pin body is movably connected with the cloth board frame, and the locking pin body can move between a locking state and a release state. In the locking state, the locking pin body sequentially passes through the first locking hole and the second locking hole to limit the partition members from passing through the opening. In the release state, the locking pin body is separated from the first locking hole and the second locking hole, so that the partition members can pass through the opening.

[0009] Further, the upper frame body includes at least two first cross beams arranged relatively and spaced apart along the first direction, and a plurality of first support beams. The first support beams extend along the first direction, and the plurality of first support beams are evenly spaced between the two first cross beams. The lower frame body includes at least two second cross beams arranged relatively and spaced apart along the first direction, and a plurality of second support beams. The second support beams extend along the first direction, and the plurality of second support beams are evenly spaced between the two second cross beams. The first support beams and the second support beams are arranged oppositely. The first locking holes are distributed on the first support beams, and the second locking holes are distributed on the second support beams.

[0010] Further, the partition member includes a partition body and a counterweight support rod body. The partition body is provided with a plurality of through holes. The counterweight support rod body is fixed at one end of one side surface of the partition body. The counterweight support rod body extends along the length direction of the partition body, and the length of the counterweight support rod body is not less than the length of the partition body.

[0011] Further, a plurality of elastic locking pins are provided on both opposite sides of the mold shell. Locking grooves are provided at both ends of the partition body along its own length direction. The elastic locking pins are movably inserted into the locking grooves in a matching manner to fit and lock the partition body and the mold shell.

[0012] Further, the driving mechanism includes two tracks that are spaced apart relative to each other along a direction perpendicular to the first direction. The tracks extend along the first direction. The mold shell is arranged between the two tracks. The driving mechanism further includes a plurality of traveling wheels. The plurality of traveling wheels are evenly distributed on both sides of the cloth laying frame. The traveling wheels are movably connected to the tracks and can move along the tracks.

[0013] Further, the driving mechanism includes a driving motor. At least one group of two traveling wheels in a relative position are connected by a driving shaft. A first transmission wheel is provided at the output end of the driving motor. A second transmission wheel is fixed on the driving shaft. The first transmission wheel is in transmission connection with the second transmission wheel. The driving motor is at least used to drive the traveling wheels to rotate so as to drive the cloth laying frame to move along the tracks.

[0014] The present invention also provides a method for forming a sleeper based on a mold device for prestressed concrete sleepers, including the following steps:

[0015] S1. Clean the mold shell, coat a release agent in the forming bin, and arrange the mold shell along the first direction;

[0016] S2. Stack a plurality of partition members in the partition storage space along the first direction. Pass the prestressed steel wires that have not been applied with force through the plurality of partition members in sequence. Drive the cloth laying frame to move along the first direction through the driving mechanism, and place the partition members in the forming bin at intervals along the first direction through the partition release mechanism to divide the forming bin into a plurality of sleeper forming spaces. Apply a force to the prestressed steel wires to tension the prestressed steel wires;

[0017] S4. Pour concrete into the sleeper forming space and vibrate;

[0018] S5. After the concrete solidifies, release the prestress of the prestressed steel wires, and cut between two adjacent partition members in the two adjacent sleeper forming spaces that are close to each other to divide them into a plurality of sleeper blocks;

[0019] S6. Demold the sleeper blocks to form sleepers, and perform appearance inspection, size measurement and subsequent processing on the sleepers.

[0020] Further, in S2, a force is applied to the prestressed steel wires through a steel wire tensioning device.

[0021] As can be seen from the above technical solutions, the advantages of the present invention are as follows:

[0022] (1) By providing a cloth board frame, a plurality of partition members are first stacked in the partition storage space along the first direction, and the through holes of the plurality of partition members are correspondingly communicated, which facilitates the prestressed steel wires to pass through the plurality of partition members in sequence, effectively reducing the length of the prestressed steel wires passing through, improving the efficiency and accuracy of passing the prestressed steel wires, effectively reducing the use of labor, reducing production costs, and improving the forming efficiency of the sleeper.

[0023] (2) By providing a partition release mechanism and a driving mechanism, during the movement of the cloth board frame driven by the driving mechanism, the partition release mechanism sequentially places the plurality of partition members with prestressed steel wires passed through at intervals in the mold shell, thereby completing the sleeper forming spaces for a plurality of formable sleepers, and thus realizing the forming of a plurality of sleepers at one time, further improving the production efficiency of the sleeper. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the technical solutions of the present invention, the drawings required for description will be briefly introduced below. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0025] Figure 1 It is a partial front structural sectional view of the mold device in an embodiment of the present invention;

[0026] Figure 2 It is a partial top view of the structure of the mold device in an embodiment of the present invention;

[0027] Figure 3 It is a schematic structural view of a partition member in an embodiment of the present invention;

[0028] Figure 4 It is a schematic structural view of a cloth board frame in an embodiment of the present invention.

[0029] Main reference numeral descriptions:

[0030] 100, Prestressed steel wire; 200, cloth board frame; 210, partition storage space; 211, opening; 220, upper frame body; 221, first locking hole; 222, first cross beam; 223, first support beam; 230, lower frame body; 231, second locking hole; 232, second cross beam; 233, second support beam; 240, vertical beam; 250, locking pin body; 300, partition member; 310, through hole; 320, partition body; 330, counterweight support rod body; 400, mold shell; 410, forming bin; 500, driving mechanism; 510, track; 520, walking wheel. Detailed implementation manners

[0031] To make the objectives, features, and advantages of the present invention more obvious and understandable, the technical solutions in the present invention will be clearly and completely described below with reference to the accompanying drawings in the specific embodiments of the present invention. Obviously, the embodiments described below are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments in this patent, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the scope of protection of this patent.

[0032] Embodiment 1

[0033] Please refer to Figures 1-4 , a mold device for prestressed concrete sleepers, including a prestressed steel wire 100, and further including a cloth board frame 200, a plurality of partition members 300, and a mold shell 400. The mold shell 400 extends in a first direction, and the mold shell 400 is provided with a forming bin 410 that opens to one side. The cloth board frame 200 is arranged on the side opposite to the forming bin 410. The cloth board frame 200 is provided with a partition storage space 210. A plurality of partition members 300 are stored in the partition storage space 210 along the first direction. The partition members 300 are provided with a plurality of through holes 310. The prestressed steel wire 100 passes through the plurality of partition members 300 in sequence through the through holes 310. The partition storage space 210 is provided with a partition release mechanism. The partition release mechanism is at least used to place the partition members 300 from the partition storage space 210 into the forming bin 410. The cloth board frame 200 is connected with a driving mechanism 500. The driving mechanism 500 is at least used to drive the cloth board frame 200 to move along the first direction, so that the partition release mechanism releases the partition members 300 at intervals along the first direction. The plurality of partition members 300 divide the forming bin 410 into a plurality of sleeper forming spaces.

[0034] In this embodiment, as Figure 1 , Figure 2As shown in the figure, the first direction is the length direction of the sleeper, that is, the length direction of the long-line production line. The mold housing 400 is placed horizontally, and its length direction is the length direction of the production line. The inside of the mold housing 400 is a hollow structure forming a molding chamber 410. The upper end surface of the mold housing 400 is an open structure for pouring concrete. A cloth board frame 200 is provided above the mold housing 400. The cloth board frame 200 can be a cuboid structure. The cloth board frame 200 is arranged horizontally and is disposed opposite to the mold housing 400. The length direction of the cloth board frame 200 is consistent with the width direction of the mold housing 400, and the width direction of the cloth board frame 200 is consistent with the length direction of the mold housing 400. A partition storage space 210 is provided inside the cloth board frame 200. The partition member 300 is a rectangular plate-like structure. The partition member 300 is placed vertically. The length direction of the partition member 300 is consistent with the length direction of the cloth board frame 200, and the width direction of the partition member 300 is consistent with the width direction of the cloth board frame 200. The partition storage space 210 is a cuboid space structure matching the external dimensions of the partition member 300. A plurality of partition members 300 are stacked in sequence in the partition storage space 210 along the first direction. Among them, the through holes 310 on the plurality of partition members 300 are correspondingly communicated in sequence. Before work, it is convenient to pass the prestressed steel wire 100 through the through holes 310 and through the partition members 300 in sequence. Specifically, a partition release mechanism is provided in the partition storage space 210. During work, the partition release mechanism can place the partition with the prestressed steel wire 100 passed through it from the partition storage space 210 into the molding chamber 410 of the mold housing 400. In addition, the cloth board frame 200 is also connected with a driving mechanism 500 for driving it to move along the length direction of the production line, so as to drive the cloth board frame 200 to move and place the partition members 300 on the mold housing 400 at intervals, so as to divide the molding chamber 410 into a plurality of sleeper molding spaces for molding sleepers.

[0035] During the working process, the long-line method of prestressed sleeper production is used. First, the mold shell 400 is arranged along the length direction of the production line. Then, a relative number of multiple partition members 300 are stacked in sequence along the length direction of the production line in the partition storage space 210. Next, the prestressed steel wires 100 without applied force are sequentially passed through the multiple partition members 300 through the through holes 310 on the partition members 300. First, the outermost partition member 300 with the prestressed steel wires 100 passed through is placed in the forming bin 410 of the mold shell 400 by the partition release mechanism. After that, the driving mechanism 500 works. The driving cloth plate frame 200 is driven to move a first distance along the length direction of the production line and then stops driving. Then, the second partition member 300 is placed by the partition release mechanism. This first distance is the length of one formed sleeper. The two partition members 300 and the mold shell 400 enclose a sleeper forming space for a sleeper. After placement, the driving mechanism 500 drives the cloth plate frame 200 to move a second distance and then stops driving. The third partition member 300 is placed by the partition release mechanism. This second distance is the distance between two sleepers for subsequent cutting operations by the cutting equipment. After placement, the driving mechanism 500 drives the cloth plate frame 200 to move a first distance, and the fourth partition member 300 is placed. By repeating the above steps, the corresponding number of partition members 300 is placed along the length direction of the mold shell 400. After that, by applying a tensile force to the prestressed steel wires 100, the prestressed steel wires 100 are tightened to reach the preset prestress, and then concrete is poured into the multiple sleeper forming spaces to complete the pouring and forming of the sleepers. In addition, in order to further increase the number of produced sleepers and production efficiency, multiple mold shells 400 can be sequentially arranged along the width direction of the production line, and the length of the partition members 300 is coordinated with the width of the multiple mold shells 400.

[0036] In the above structure, by setting the cloth plate frame 200, first, multiple partition members 300 are stacked in the partition storage space 210 along the first direction, and the through holes 310 of the multiple partition members 300 are correspondingly connected. Thus, it is convenient to sequentially pass the prestressed steel wires 100 through the multiple partition members 300, effectively reducing the length for the prestressed steel wires 100 to pass through, thereby improving the efficiency and accuracy of passing the prestressed steel wires 100, effectively reducing the use of labor, lowering the production cost, and improving the sleeper forming efficiency. In addition, by setting the partition release mechanism and the driving mechanism 500, during the movement of the driving mechanism 500 driving the cloth plate frame 200, the partition release mechanism sequentially and intermittently places the multiple partition members 300 with the prestressed steel wires 100 passed through in the mold shell 400, thereby completing the sleeper forming spaces for multiple formable sleepers, and thus realizing the forming of multiple sleepers at one time, further improving the production efficiency of the sleepers.

[0037] In the specific structure of the cloth board frame 200, the cloth board frame 200 includes an upper frame body 220 and a lower frame body 230 which are relatively spaced apart. One end of the upper frame body 220 in the first direction and one end of the lower frame body 230 in the first direction are connected with a plurality of vertical beams 240. The other ends of the upper frame body 220 and the lower frame body 230 form an opening 211 for the partition member 300 to pass through. The upper frame body 220, the lower frame body 230 and the plurality of vertical beams 240 enclose a storage space.

[0038] In this embodiment, as Figure 2 shown, the upper frame body 220 can be a rectangular plate-like structure, and the lower frame body 230 is also a rectangular plate-like structure accordingly. The upper frame body 220 and the lower frame body 230 are both arranged in the horizontal direction, and the upper frame body 220 and the lower frame body 230 are spaced apart in the vertical direction. The upper frame body 220 is located above the lower frame body 230. Between the upper frame body 220 and the lower frame body 230, and at one end in the width direction of the cloth board frame 200, a plurality of vertically arranged vertical beams 240 are connected. Among them, the upper frame body 220, the lower frame body 230 and the plurality of vertical beams 240 enclose a rectangular space to form a partition storage space 210. In addition, rectangular openings 211 are formed at one ends of the upper frame body 220 and the lower frame body 230 opposite to the vertical beams 240, so as to facilitate the placement of the partition member 300 into the mold housing 400 from the opening 211.

[0039] In the above structure, the frame structure enclosed by the upper frame body 220, the lower frame body 230 and the plurality of vertical beams 240 provides a stable space for storing the partition member 300, and can effectively bear the weight of the partition member 300 and various acting forces generated during the moving process, ensuring that the cloth board frame 200 will not be deformed or damaged during the working process.

[0040] In the structure of the partition release mechanism, the upper frame body 220 includes a plurality of first hole groups evenly spaced in the first direction. Each first hole group includes a plurality of first locking holes 221 evenly spaced perpendicular to the first direction. The lower frame body 230 includes a plurality of second hole groups evenly spaced in the first direction. Each second hole group includes a plurality of second locking holes 231 evenly spaced perpendicular to the first direction. And the first locking holes 221 and the second locking holes 231 are arranged opposite to each other. The partition release mechanism includes a locking component. The locking component includes a locking pin body 250. The locking pin body 250 is movably connected to the cloth board frame 200, and the locking pin body 250 can move between a locking state and a release state. In the locking state, the locking pin body 250 sequentially passes through the first locking hole 221 and the second locking hole 231 to limit the partition member 300 from passing through the opening 211. In the release state, the locking pin body 250 is separated from the first locking hole 221 and the second locking hole 231, so that the partition member 300 can pass through the opening 211.

[0041] In this embodiment, the partition release mechanism includes a locking pin body 250, which is movably connected to the panel frame 200 and can move in the vertical direction. A plurality of first hole groups are distributed along the width direction of the upper frame 220, and the plurality of first hole groups are evenly spaced. Each first hole group includes a plurality of first locking holes 221, and the first locking holes 221 are evenly spaced along the width direction of the upper frame 220. The structure of the lower frame 230 corresponds to that of the upper frame 220, and is also provided with a plurality of second hole groups evenly spaced along its own width direction. Each second hole group includes a plurality of second locking holes 231 evenly spaced along its own length direction, and the second locking holes 231 are arranged opposite to the first locking holes 221 on the upper frame 220. The size, shape and distribution pattern of the second locking holes 231 are consistent with those of the first locking holes 221 to ensure that in the locked state, the locking pin body 250 can pass through the first locking hole 221 and the second locking hole 231 at the same time, thereby achieving effective restriction on the partition member 300.

[0042] In the initial state, the locking pin body 250 is in a locked state. At this time, the locking pin body 250 passes through the first locking hole 221 and the second locking hole 231 in sequence, thereby blocking the opening 211, effectively restricting the partition member 300 from passing through the opening 211, so as to restrict the movement of the partition member 300. When the partition member 300 needs to be released, the locking pin body 250 is moved upward in the vertical direction, so that the locking pin body 250 is separated from the second locking hole 231 and the second locking hole 231, thereby releasing the blockage of the opening 211, and then the partition member 300 is placed from the partition storage space 210 through the opening 211 to the corresponding position of the mold shell 400 by the existing technical forms such as a mechanical arm or manual operation, so as to realize the release of the partition member 300.

[0043] Through the cooperation between the locking pin body 250 and the first locking hole 221 and the second locking hole 231, the release timing and position of the partition member 300 can be accurately controlled. In the locked state, the locking pin body 250 can reliably limit the movement of the partition member 300, preventing the partition member 300 from accidentally falling when it does not need to be released, thereby avoiding injury to the operator and damage to the mold device and the sleeper being formed.

[0044] In particular, the size and shape of the first locking hole 221 and the second locking hole 231 are closely matched with the locking pin body 250, for example, the inner diameter thereof is slightly larger than the outer diameter of the locking pin body 250 by 0.5-1 mm, so as to ensure that the locking pin body 250 can pass smoothly without causing excessive shaking. In addition, the number of the first hole group and the second hole group and the number of the first locking holes 221 and the second locking holes 231 in each hole group are determined according to the length of the panel frame 200 and the positioning accuracy requirements for the partition member 300.

[0045] More specifically, the upper frame body 220 includes at least two first cross beams 222 arranged at intervals relative to each other in the first direction, and a plurality of first support beams 223. The first support beams 223 extend in the first direction, and the plurality of first support beams 223 are evenly spaced between the two first cross beams 222. The lower frame body 230 includes at least two second cross beams 232 arranged at intervals relative to each other in the first direction, and a plurality of second support beams 233. The second support beams 233 extend in the first direction, and the plurality of second support beams 233 are evenly spaced between the two second cross beams 232. The first support beams 223 and the second support beams 233 are arranged opposite to each other. The first locking holes 221 are distributed on the first support beams 223, and the second locking holes 231 are distributed on the second support beams 233.

[0046] In this embodiment, as Figure 4 shown, the upper frame body 220 includes first cross beams 222 and a plurality of first support beams 223. At least two first cross beams 222 are arranged at intervals relative to each other in the width direction of the upper frame body 220. The plurality of first support beams 223 are evenly spaced between the two first cross beams 222 and extend in the width direction of the upper frame body 220. The function of the first support beams 223 is to assist the first cross beams 222 and enhance the overall stability of the upper frame body 220. At the same time, it provides an installation position for the first locking holes 221. Corresponding to the first cross beams 222 of the upper frame body 220, the lower frame body 230 is also provided with at least two second cross beams 232 arranged at intervals relative to each other in the width direction of the lower frame body 230. Among them, the function and structural characteristics of the second cross beams 232 are similar to those of the first cross beams 222. The plurality of second support beams 233 are evenly spaced between the two second cross beams 232 and extend in the width direction of the lower frame body 230. The second support beams 233 are arranged opposite to the first support beams 223, and their dimensions, materials, and distribution intervals are basically the same. The second locking holes 231 are distributed on the second support beams 233 and are aligned with the first locking holes 221 on the first support beams 223 in the vertical direction to ensure that the locking pin body 250 can smoothly pass through the first locking holes 221 and the second locking holes 231 to achieve effective locking of the partition member 300.

[0047] The combined structure of the first cross beams 222 and the plurality of first support beams 223, and the second cross beams 232 and the plurality of second support beams 233 greatly enhances the overall strength and stability of the upper frame body 220 and the lower frame body 230. And the installation and connection of this structure are relatively convenient. For example, common connection methods such as welding and bolt connection can be used between the first cross beams 222 and the first support beams 223, and between the second cross beams 232 and the second support beams 233, which is convenient for assembly at the production site. Moreover, when a certain component is damaged, since its structure is relatively independent, it is relatively easy to replace. At the same time, this structure can effectively reduce the overall mass of the upper frame body 220 and the lower frame body 230, which is convenient for lightweight production.

[0048] In the specific structure of the partition member 300, the partition member 300 includes a partition body 320 and a counterweight support rod body 330. The partition body 320 is provided with a plurality of through holes 310. The counterweight support rod body 330 is fixed at one end of a side surface of the partition body 320. The counterweight support rod body 330 extends along the length direction of the partition body 320, and the length of the counterweight support rod body 330 is not less than the length of the partition body 320.

[0049] In this embodiment, as Figure 3 shown, the partition body 320 is a rectangular plate-like structure. A counterweight support rod body 330 is fixed at the lower end of one end surface of the partition body 320 in the thickness direction. Among them, the length direction of the counterweight support rod body 330 is consistent with the length direction of the partition body 320, and the length of the counterweight support rod body 330 is greater than or equal to the length of the partition body 320, so that the counterweight support plate body can effectively support the partition body 320, effectively avoiding the deformation of the partition body 320, and causing a gap between the partition body 320 and the mold shell 400, thus easily allowing the concrete to leak out from this gap during the pouring process. Fixing the counterweight support rod body 330 on the partition body 320 makes it easier for the partition body 320 to fit and connect with the mold shell 400 when the partition member 300 is released.

[0050] Specifically, a plurality of elastic locking pins are provided on both opposite sides of the mold shell 400. Locking grooves are provided at both ends of the partition body 320 along its own length direction. The elastic locking pins can be movably inserted into the locking grooves in a matching manner to fit and lock the partition body 320 and the mold shell 400.

[0051] In this embodiment, a plurality of elastic locking pins are evenly distributed on opposite sides of the mold housing 400 along its width direction. The elastic locking pin is a prior art. For example, the elastic locking pin mainly consists of a pin body, a spring, and a mounting seat. One end of the pin body is a working end for inserting into the locking groove of the partition body 320. The shape of the working end matches the locking groove, generally being cylindrical, and the end can be designed with a slight taper for easy insertion. The other end of the pin body is connected to the spring, and the spring is sleeved on the pin body. The mounting seat is fixed on the mold housing 400 for accommodating the spring and supporting the pin body to ensure the stable installation of the elastic locking pin on the mold housing 400. Locking grooves are provided at both ends of the partition body 320 along its own length direction. The shape and size of the locking grooves match the working end of the elastic locking pin to ensure that the elastic locking pin can be smoothly inserted and closely fitted. After the partition member 300 falls into the molding bin 410, the operator slightly adjusts the position of the partition member 300 to align the locking groove with the elastic locking pin. After the partition body 320 is locked with the mold housing 400, due to the close fit between the elastic locking pin and the locking groove, the partition body 320 is firmly fixed on the mold housing 400. Under the large impact force generated during concrete pouring and the strong vibration during the vibration process, the partition body 320 will not displace or shake, ensuring the stability of the shape and size of the sleeper molding space.

[0052] In the specific structure of the driving mechanism 500, the driving mechanism 500 includes two tracks 510 that are spaced apart relative to each other along a direction perpendicular to the first direction. The tracks 510 extend along the first direction, and the mold housing 400 is arranged between the two tracks 510. The driving mechanism 500 further includes a plurality of traveling wheels 520. The plurality of traveling wheels 520 are evenly distributed on both sides of the cloth laying frame 200. The traveling wheels 520 are movably connected to the tracks 510 and can move along the tracks 510. The driving mechanism 500 includes a driving motor. At least one set of two traveling wheels 520 in a relative position are connected by a driving shaft. A first transmission wheel is provided at the output end of the driving motor, and a second transmission wheel is fixed on the driving shaft. The first transmission wheel is in transmission connection with the second transmission wheel. The driving motor is at least used to drive the traveling wheels 520 to rotate to drive the cloth laying frame 200 to move along the tracks 510.

[0053] In this embodiment, as Figure 2As shown in the figure, there are two tracks 510 arranged at intervals in the width direction of the cloth board frame 200. Among them, the extending direction of the track 510 is the length direction of the production line. The mold housing 400 is arranged between the two tracks 510. A plurality of walking wheels 520 are evenly distributed on both sides in the width direction of the cloth board frame 200. The number of the walking wheels 520 is reasonably configured according to the length and load-bearing capacity of the cloth board frame 200. Generally, a set of walking wheels 520 is installed at a certain distance. Among them, the walking wheels 520 cooperate with the tracks 510, so that the walking wheels 520 move on the tracks 510. The tracks 510 provide guiding and limiting functions for the walking wheels 520. The walking wheels 520 can reduce the friction when the cloth board frame 200 moves and further improve the moving efficiency of the cloth board frame 200. In addition, a set of walking wheels 520 at one end of the cloth board frame 200 is connected by a drive shaft. A second transmission wheel is fixed on the drive shaft. A first transmission wheel is installed on the output shaft of the drive motor. The type of the first transmission wheel can be a belt pulley, a sprocket or a gear. The type of the second transmission wheel matches that of the first transmission wheel. When the mold device needs to operate, the drive motor is started. After the drive motor is powered on, it starts to operate. Its output shaft drives the first transmission wheel to rotate. Due to the transmission connection between the first transmission wheel and the second transmission wheel, the second transmission wheel rotates with the rotation of the first transmission wheel. The second transmission wheel is installed on the drive shaft, and the drive shaft is connected to the walking wheels 520. Therefore, the drive shaft drives the walking wheels 520 to rotate. A plurality of walking wheels 520 are evenly distributed on both sides of the cloth board frame 200. During the rotation of the walking wheels 520, the cloth board frame 200 moves along the track 510 in the first direction.

[0054] Through the cooperation of the drive motor, the transmission wheels and the drive shaft, the rotation speed and direction of the walking wheels 520 can be accurately controlled, ensuring that the partition members 300 are accurately placed in the forming bin 410 at a predetermined interval, and improving the dimensional accuracy and quality stability of the produced prestressed concrete sleepers.

[0055] Embodiment 2

[0056] The present invention also provides a sleeper forming method based on the mold device for prestressed concrete sleepers, including the following steps:

[0057] S1. Clean the mold housing 400, coat a release agent in the forming bin 410, and set the mold housing 400 in the first direction.

[0058] In this step, use special cleaning tools such as wire brushes and vacuum cleaners to remove impurities such as residual concrete, dust, and oil stains on the inner surface of the mold housing 400, creating a foundation for subsequent application of the release agent and concrete pouring. Select a suitable release agent and choose the corresponding coating method according to the type of release agent. If it is an oil-based release agent, it can be sprayed with a spray gun; if it is a water-based release agent, a brush can also be used for brushing to ensure a uniform coating thickness. Then place the mold housing 400 in a pre-determined working position in the first direction (i.e., the forming direction of the sleeper). Mold cleaning and release agent coating ensure good separation between the concrete and the mold, effectively reducing defects on the surface of the sleeper and improving the appearance quality of the sleeper.

[0059] S2. Stack multiple partition members 300 in the partition storage space 210 along the first direction. Pass the unloaded prestressed steel wire 100 through the multiple partition members 300 in sequence. Drive the cloth plate frame 200 to move along the first direction through the driving mechanism 500, and place the partition members 300 at intervals in the forming chamber 410 along the first direction through the partition release mechanism to divide the forming chamber 410 into multiple sleeper forming spaces. Apply a force to the prestressed steel wire 100 to tension the prestressed steel wire 100. Additionally, in S2, a force is applied to the prestressed steel wire 100 by a steel wire tensioning device.

[0060] In this step, stack multiple partition members 300 in sequence along the first direction in the partition storage space 210 of the cloth plate frame 200. During the stacking process, keep the partition members 300 neat and stable. Pass the unloaded prestressed steel wire 100 through the multiple partition members 300 through the through holes 310 in sequence. Start the driving mechanism 500. The driving motor drives the first transmission wheel to rotate. Through transmission methods such as transmission belts, chains, or gears, the power is transmitted to the second transmission wheel, and then drives the drive shaft and the walking wheels 520 to rotate, causing the cloth plate frame 200 to move along the track 510 in the first direction. When the cloth plate frame 200 moves to a specific position, the partition release mechanism starts to work, placing the partition members 300 at intervals in the forming chamber 410 and dividing the forming chamber 410 into multiple sleeper forming spaces. After the partition members 300 are placed, use professional steel wire tensioning equipment such as a jack or a tensioning machine to apply a tensile force to the prestressed steel wire 100 to make the prestressed steel wire 100 reach the predetermined tensile stress value. By setting the driving mechanism 500 and the partition release mechanism, the time for passing the prestressed steel wire 100 through the partition members 300 and placing them is greatly shortened, improving the production efficiency.

[0061] S4. Pour the concrete into the sleeper forming space and vibrate it. In this step, the well-mixed concrete is slowly poured into each sleeper forming space separated by the partition member 300 through a concrete conveying device such as a concrete pump truck or a hopper. While pouring the concrete, start the vibrating device such as an internal vibrator or a screed vibrator to vibrate the concrete to remove the air in the concrete, make the concrete more dense, and improve the strength and durability of the sleeper.

[0062] S5. After the concrete solidifies, release the prestress of the prestressed steel wire 100 and cut between two adjacent partition members 300 in the adjacent two sleeper forming spaces to divide it into multiple sleeper blocks. In this step, after the concrete solidifies to a certain strength, use a professional prestress release device such as a tensioning machine to slowly release the prestress of the prestressed steel wire 100. Then, use a cutting device such as a power saw or a water jet cutter to cut between two adjacent partition members 300 in the adjacent two sleeper forming spaces to divide the whole piece of concrete into multiple sleeper blocks.

[0063] S6. Demold the sleeper blocks to form sleepers, and conduct appearance inspection, dimension measurement and subsequent processing on the sleepers.

[0064] In this step, use a demolding tool such as a crowbar or a demolder to carefully remove the formed sleeper from the mold housing 400. Then, conduct an appearance inspection on the demolded sleeper to observe whether there are defects such as cracks, pitted surfaces, and honeycombs on the surface of the sleeper. Links such as appearance inspection and dimension measurement can timely detect the quality problems existing in the sleepers, which is convenient for quality control and adjustment of the production process.

[0065] The above description of the disclosed embodiments enables those skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to those skilled in the art, and the general principles defined herein can be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to these embodiments shown herein, but will be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A die device for prestressed concrete sleepers, including prestressed steel wires, characterized in that, It further includes a cloth board frame, a plurality of partition members and a die shell. The die shell extends along a first direction, and the die shell is provided with a forming bin opening towards one side. The cloth board frame is arranged on the side opposite to the forming bin. The cloth board frame is provided with a partition storage space. A plurality of the partition members are stored in the partition storage space along the first direction. The partition members are provided with a plurality of through holes, and the prestressed steel wires pass through the plurality of partition members in sequence through the through holes. The partition storage space is provided with a partition release mechanism, and the partition release mechanism is at least used to place the partition members from the partition storage space into the forming bin. The cloth board frame is connected with a driving mechanism, and the driving mechanism is at least used to drive the cloth board frame to move along the first direction, so that the partition release mechanism releases the partition members at intervals along the first direction. The plurality of partition members divide the forming bin into a plurality of sleeper forming spaces.

2. The mold device for a prestressed concrete sleeper according to claim 1, wherein The cloth board frame includes an upper frame body and a lower frame body which are arranged relatively and spaced apart. One end of the upper frame body along the first direction and one end of the lower frame body along the first direction are connected with a plurality of vertical beams. The other ends of the upper frame body and the lower frame body form an opening for the partition members to pass through. The upper frame body, the lower frame body and the plurality of vertical beams enclose the storage space.

3. The mold device for a prestressed concrete sleeper according to claim 2, characterized in that, The upper frame body includes a plurality of first hole groups which are evenly spaced along the first direction. Each first hole group includes a plurality of first locking holes which are evenly spaced along a direction perpendicular to the first direction. The lower frame body includes a plurality of second hole groups which are evenly spaced along the first direction. Each second hole group includes a plurality of second locking holes which are evenly spaced along a direction perpendicular to the first direction. And the first locking holes and the second locking holes are arranged oppositely. The partition release mechanism includes a locking component. The locking component includes a locking pin body. The locking pin body is movably connected with the cloth board frame, and the locking pin body can move between a locking state and a release state. In the locking state, the locking pin body passes through the first locking hole and the second locking hole in sequence to limit the partition members from passing through the opening. In the release state, the locking pin body is separated from the first locking hole and the second locking hole, so that the partition members can pass through the opening.

4. The mold device for a prestressed concrete sleeper according to claim 3, characterized in that, The upper frame body includes at least two first cross beams which are relatively spaced along the first direction, and a plurality of first support beams. The first support beams extend along the first direction, and a plurality of the first support beams are evenly spaced between the two first cross beams. The lower frame body includes at least two second cross beams which are relatively spaced along the first direction, and a plurality of second support beams. The second support beams extend along the first direction, and a plurality of the second support beams are evenly spaced between the two second cross beams. The first support beams and the second support beams are arranged oppositely. The first locking holes are distributed on the first support beams, and the second locking holes are distributed on the second support beams.

5. The mold device for a prestressed concrete sleeper according to claim 1, characterized in that, The partition member includes a partition body and a counterweight support rod body. The partition body is provided with a plurality of the through holes. The counterweight support rod body is fixed at one end of one side surface of the partition body. The counterweight support rod body extends along the length direction of the partition body, and the length of the counterweight support rod body is not less than the length of the partition body.

6. The mold device for a prestressed concrete sleeper according to claim 5, characterized in that, A plurality of elastic locking pins are provided on both opposite sides of the mold shell. Locking grooves are provided at both ends of the partition body along its own length direction. The elastic locking pins can be movably inserted into the locking grooves in a matching manner to fit and lock the partition body and the mold shell.

7. The mold device for a prestressed concrete sleeper according to claim 1, characterized in that, The driving mechanism includes two tracks that are relatively spaced apart along a direction perpendicular to the first direction. The tracks extend along the first direction. The mold shell is arranged between the two tracks. The driving mechanism further includes a plurality of traveling wheels. The plurality of traveling wheels are evenly distributed on both sides of the cloth plate frame. The traveling wheels are movably connected to the tracks and can move along the tracks.

8. The mold device for a prestressed concrete sleeper according to claim 7, characterized in that, The driving mechanism includes a driving motor. At least one group of two traveling wheels in a relative position are connected by a driving shaft. A first transmission wheel is provided at the output end of the driving motor. A second transmission wheel is fixed on the driving shaft. The first transmission wheel is in transmission connection with the second transmission wheel. The driving motor is at least used to drive the traveling wheels to rotate so as to drive the cloth plate frame to move along the tracks.

9. A method for forming a sleeper using the mold device for a prestressed concrete sleeper according to any one of claims 1-8, characterized in that, It includes the following steps S1. Clean the mold shell, coat a mold release agent in the molding bin, and arrange the mold shell along the first direction. S2. Stack a plurality of the partition members along the first direction in the partition storage space. Pass the prestressed steel wires that have not been applied with force through the plurality of partition members in sequence. Drive the cloth plate frame to move along the first direction through the driving mechanism, and place the partition members at intervals along the first direction in the molding bin through the partition release mechanism to divide the molding bin into a plurality of sleeper molding spaces. Apply a force to the prestressed steel wires to tension the prestressed steel wires. S4. Pour concrete into the sleeper molding spaces and vibrate. S5. After the concrete solidifies, release the prestress of the prestressed steel wires, and cut between two adjacent partition members in two adjacent sleeper molding spaces that are close to each other to divide them into a plurality of sleeper blocks. S6. Demold the sleeper blocks to form sleepers, and conduct appearance inspection, dimension measurement and subsequent processing on the sleepers.

10. The method for forming a sleeper according to claim 9, characterized in that, In S2, a wire tensioning device is used to apply a force to the prestressed steel wires.

Images