A mold device for prestressed concrete sleepers and a sleeper forming method

Abstract

The application provides a prestressed concrete sleeper mold device and a sleeper forming method, and belongs to the technical field of sleeper production equipment. The technical scheme of the prestressed concrete sleeper mold device comprises prestressed steel wires, a cloth plate frame, a plurality of partition plate pieces and a mold shell. The mold shell extends along a first direction. The cloth plate frame is provided with a partition plate storage space. The plurality of partition plate pieces are stored in the partition plate storage space along the first direction. The prestressed steel wires pass through the plurality of partition plate pieces in sequence. The cloth plate frame is connected with a driving mechanism. The cloth plate frame is driven to move along the first direction. A partition plate releasing mechanism releases the partition plate pieces along the first direction at intervals. The plurality of partition plate pieces divide a forming bin into a plurality of sleeper forming spaces. The plurality of partition plate pieces are stacked in the partition plate storage space along the first direction. The prestressed steel wires pass through the plurality of partition plate pieces in sequence. The length of the prestressed steel wires is reduced. The efficiency of the prestressed steel wires is improved. The sleeper forming efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of railway sleeper production equipment technology, and in particular to a mold device and a method for forming prestressed concrete railway sleepers. Background Technology

[0002] Prestressed concrete sleepers are an important component of railway tracks and are widely used in high-speed railways, urban rail transit, and conventional railways. Reinforced with prestressing technology, these sleepers can withstand greater loads and deformations, improving the overall stability of the track structure and contributing to enhanced train safety and smoothness. Furthermore, the prefabrication process and factory production reduce on-site work and significantly shorten the construction cycle. Prestressed concrete sleepers also have a long service life, reducing maintenance frequency and costs.

[0003] In the production of prestressed concrete railway sleepers, a long-line method is typically used to improve production efficiency. This method involves distributing sleeper molds along one direction, then sequentially threading unstressed steel wires through multiple molds. Prestress is then applied to the wires to tighten them, and concrete is poured into the molds to complete the sleeper production. However, this method usually requires manual operation to thread the wires through the molds. Because the sleeper molds are long and include multiple partitions, the alignment speed for threading the wires is slow, resulting in low efficiency. Consequently, the production efficiency of the sleepers is low, and it consumes a significant amount of manpower, increasing production costs. Summary of the Invention

[0004] This invention addresses the problem that the current long-line method for producing prestressed railway sleepers typically involves manually threading steel wires into the sleeper mold, resulting in low production efficiency and high production costs. It proposes a mold device and sleeper forming method for prestressed concrete railway sleepers.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] This invention provides a mold device for prestressed concrete railway sleepers, including prestressed steel wires, a fabrication frame, multiple partitions, and a mold shell. The mold shell extends along a first direction and has a forming chamber with an opening to one side. The fabrication frame is located on the side opposite to the forming chamber and has a partition storage space. Multiple partitions are stored in the partition storage space along the first direction. Each partition has multiple through holes through which the prestressed steel wires pass sequentially. The partition storage space has a partition release mechanism, which is at least used to place the partitions from the partition storage space into the forming chamber. The fabrication frame is connected to a driving mechanism, which is at least used to drive the fabrication frame to move along the first direction, so that the partition release mechanism releases the partitions at intervals along the first direction. The multiple partitions divide the forming chamber into multiple sleeper forming spaces.

[0007] Furthermore, the fabric frame includes an upper frame and a lower frame arranged at relatively intervals. One end of the upper frame along a first direction and one end of the lower frame along a first direction are connected to multiple vertical beams. The other ends of the upper frame and the lower frame form openings for the partition members to pass through. The upper frame, the lower frame, and the multiple vertical beams enclose a storage space.

[0008] Furthermore, the upper frame includes a plurality of first hole groups evenly spaced along a first direction, each first hole group including a plurality of first locking holes evenly spaced perpendicular to the first direction; the lower frame includes a plurality of second hole groups evenly spaced along the first direction, each second hole group including a plurality of second locking holes evenly spaced perpendicular to the first direction; the first locking holes and the second locking holes are arranged opposite to each other; the partition release mechanism includes a locking assembly, which includes a locking pin, which is movably connected to the fabric frame; the locking pin can be in a locked state and a released state; in the locked state, the locking pin passes through the first locking hole and the second locking hole in sequence to restrict the partition from passing through the opening; in the released state, the locking pin separates from the first locking hole and the second locking hole to allow the partition to pass through the opening.

[0009] Furthermore, the upper frame includes at least two first crossbeams arranged at intervals relative to each other along a 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 crossbeams. The lower frame includes at least two second crossbeams arranged at intervals relative to each other 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 crossbeams. The first support beams and the second support beams are arranged opposite to each other. First locking holes are distributed on the first support beams, and second locking holes are distributed on the second support beams.

[0010] Furthermore, the partition component includes a partition body and a counterweight support rod. The partition body has multiple through holes, and the counterweight support rod is fixed to one end of one side of the partition body. The counterweight support rod extends along the length of the partition body, and the length of the counterweight support rod is not less than the length of the partition body.

[0011] Furthermore, the mold housing is provided with multiple elastic locking pins on both sides, and the partition body is provided with locking grooves at both ends along its own length direction. The elastic locking pins can be movably engaged with the locking grooves to fit and lock the partition body and the mold housing together.

[0012] Furthermore, the drive mechanism includes two tracks that are relatively spaced apart along a direction perpendicular to the first direction. The tracks extend along the first direction, and the mold housing is located between the two tracks. The drive mechanism also includes multiple traveling wheels that are evenly distributed on both sides of the fabric frame. The traveling wheels are movably connected to the tracks and can move along the tracks.

[0013] Furthermore, the drive mechanism includes a drive motor, at least one set of two traveling wheels in relative positions connected by a drive shaft, the output end of the drive motor is provided with a first transmission wheel, the drive shaft is fixed with a second transmission wheel, the first transmission wheel and the second transmission wheel are connected in transmission, and the drive motor is used at least to drive the traveling wheels to rotate, so as to drive the fabric frame to move along the track.

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

[0015] S1. Clean the mold shell, apply a release agent to the molding chamber, and set the mold shell along the first direction;

[0016] S2. Stack multiple partition pieces along the first direction in the partition storage space, pass the unstressed prestressed steel wire through the multiple partition pieces in sequence, drive the board frame to move along the first direction through the drive mechanism, and place the partition pieces at intervals along the first direction in the forming chamber through the partition release mechanism to divide the forming chamber into multiple sleeper forming spaces, and apply force to the prestressed steel wire to tighten the prestressed steel wire.

[0017] S3. Pour concrete into the sleeper forming space and vibrate it;

[0018] S4. After the concrete has solidified, release the prestress of the prestressed steel wires and cut the two adjacent partitions in the forming space of two adjacent sleepers to divide them into multiple sleeper blocks.

[0019] S5. Demold the sleeper blocks to form sleepers, and perform appearance inspection, dimensional measurement and subsequent processing on the sleepers.

[0020] Furthermore, in S2, the prestressed steel wire is subjected to force by a steel wire tensioning device.

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

[0022] (1) By setting up a plate frame, the present invention first stacks multiple partitions along the first direction in the partition storage space. The through holes of the multiple partitions are connected to each other, which makes it convenient to pass the prestressed steel wire through the multiple partitions in sequence. This effectively reduces the length of the prestressed steel wire, improves the efficiency and accuracy of passing the prestressed steel wire, effectively reduces the use of manual labor, reduces production costs, and improves the sleeper forming efficiency.

[0023] (2) By setting up a partition release mechanism and a driving mechanism, during the process of the driving mechanism driving the cloth frame to move, the partition release mechanism will place multiple partition pieces with prestressed steel wires in the mold shell in sequence at intervals, thereby completing the sleeper forming space of multiple formable sleepers, thus realizing the one-time forming of multiple sleepers and further improving the efficiency of sleeper production. Attached Figure Description

[0024] To more clearly illustrate the technical solution of the present invention, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a partial cross-sectional view of the front structure of the mold device in one embodiment of the present invention;

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

[0027] Figure 3 This is a schematic diagram of the partition component in one embodiment of the present invention;

[0028] Figure 4 This is a schematic diagram of the structure of the fabric plate frame in one embodiment of the present invention.

[0029] Explanation of key figure labels:

[0030] 100. Prestressed steel wire; 200. Fabric frame; 210. Partition storage space; 211. Opening; 220. Upper frame; 221. First locking hole; 222. First crossbeam; 223. First support beam; 230. Lower frame; 231. Second locking hole; 232. Second crossbeam; 233. Second support beam; 240. Vertical beam; 250. Locking pin; 300. Partition piece; 310. Through hole; 320. Partition body; 330. Counterweight support rod; 400. Mold shell; 410. Forming chamber; 500. Drive mechanism; 510. Track; 520. Wheels. Detailed Implementation

[0031] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings of the specific embodiments. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this patent, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this patent.

[0032] Example 1

[0033] Please see Figures 1-4 A mold device for prestressed concrete railway sleepers includes a prestressed steel wire 100, a fabrication frame 200, multiple partition members 300, and a mold shell 400. The mold shell 400 extends along a first direction and has a forming chamber 410 opening to one side. The fabrication frame 200 is located on the side opposite to the forming chamber 410 and has a partition storage space 210. Multiple partition members 300 are stored in the partition storage space 210 along the first direction. Each partition member 300 has multiple through holes 310. The steel wire 100 passes through multiple partitions 300 sequentially through the through hole 310. The partition storage space 210 is provided with a partition release mechanism. The partition release mechanism is at least used to place the partitions 300 from the partition storage space 210 into the forming chamber 410. The board frame 200 is connected to a drive mechanism 500. The drive mechanism 500 is at least used to drive the board frame 200 to move along a first direction, so that the partition release mechanism releases the partitions 300 at intervals along the first direction. The multiple partitions 300 divide the forming chamber 410 into multiple sleeper forming spaces.

[0034] In this embodiment, as Figure 1 , Figure 2As shown, the first direction is the length direction of the sleeper, i.e., the length direction of the long-line production line. The mold shell 400 is placed horizontally, and its length direction is the length direction of the production line. The interior of the mold shell 400 is a hollow structure forming a molding chamber 410. The upper end face of the mold shell 400 is an open structure for concrete pouring. A fabric frame 200 is provided on the upper side of the mold shell 400. The fabric frame 200 can be a cuboid structure. The fabric frame 200 is set horizontally and opposite to the mold shell 400. The length direction of the fabric frame 200 is consistent with the width direction of the mold shell 400, and the width direction of the fabric frame 200 is consistent with the length direction of the mold shell 400. The fabric frame 200 has a partition storage space 210 inside. The partition 300 is a rectangular plate structure. The partition 300 is placed vertically, and the length direction of the partition 300 is consistent with the length direction of the fabric frame 200, and the width direction of the partition 300 is consistent with the length direction of the fabric frame 200. The width of the plate frame 200 is consistent. The partition storage space 210 is a cuboid space structure that matches the external dimensions of the partition 300. Multiple partitions 300 are stacked sequentially in the partition storage space 210 along the first direction. The through holes 310 on the multiple partitions 300 are sequentially connected to each other. Before operation, it is convenient to pass the prestressed steel wire 100 through the through holes 310 sequentially through the partitions 300. Specifically, a partition release mechanism is provided in the partition storage space 210. During operation, the partition release mechanism can place the partition with the prestressed steel wire 100 inserted from the partition storage space 210 into the forming chamber 410 of the mold housing 400. In addition, the plate frame 200 is also connected to a drive mechanism 500 that drives it to move along the length of the production line. This allows the plate frame 200 to move and place the partitions 300 on the mold housing 400 at intervals to divide the forming chamber 410 into multiple sleeper forming spaces for forming sleepers.

[0035] During operation, the long-line method for producing prestressed sleepers is used. First, the mold housing 400 is set along the length of the production line. Then, a relative number of partition pieces 300 are stacked sequentially in the partition storage space 210 along the length of the production line. Next, the unstressed prestressed steel wires 100 are passed through the through holes 310 on the partition pieces 300 sequentially. The outermost partition piece 300 with the prestressed steel wires 100 is placed in the forming chamber 410 of the mold housing 400 by the partition release mechanism. Then, the drive mechanism 500 operates, driving the plate frame 200 along the production line. After moving a first distance along the length direction, the drive mechanism 500 stops. Then, a second partition 300 is placed via the partition release mechanism. This first distance is the length of one formed sleeper. The two partitions 300 and the mold housing 400 form a sleeper forming space. After placement, the drive mechanism 500 drives the board frame 200 to move a second distance and then stops. A third partition 300 is placed via the partition release mechanism. This second distance is the distance between two sleepers for subsequent cutting operations by the cutting equipment. After placement, the drive mechanism 500 drives the board frame 200 to move a first distance to place a fourth partition 300. By repeating the above steps, a corresponding number of partitions 300 are placed along the length direction of the mold housing 400. Then, tension is applied to the prestressed steel wire 100 to achieve the preset prestress. Finally, concrete is poured into the multiple sleeper forming spaces to complete the sleeper casting and forming process. In addition, in order to further increase the quantity and efficiency of sleeper production, multiple mold housings 400 can be arranged sequentially along the width of the production line, and the length of the partition 300 can match the width of the multiple mold housings 400.

[0036] In the above structure, by setting up the plate frame 200, multiple partition pieces 300 are first stacked in the partition storage space 210 along the first direction. The through holes 310 of the multiple partition pieces 300 are correspondingly connected, which facilitates the sequential passing of the prestressed steel wire 100 through the multiple partition pieces 300, effectively reducing the length of the prestressed steel wire 100, thereby improving the efficiency and accuracy of threading the prestressed steel wire 100, effectively reducing the use of manual labor, reducing production costs, and improving the sleeper forming efficiency. In addition, by setting up the partition release mechanism and the drive mechanism 500, during the movement of the plate frame 200 driven by the drive mechanism 500, the partition release mechanism sequentially and spaced the multiple partition pieces 300 with the prestressed steel wire 100 threaded on them in the mold shell 400, thereby completing the sleeper forming space for multiple formable sleepers, thus realizing the one-time forming of multiple sleepers, further improving the efficiency of sleeper production.

[0037] In the specific structure of the panel frame 200, the panel frame 200 includes an upper frame 220 and a lower frame 230 arranged at relatively intervals. One end of the upper frame 220 along the first direction and one end of the lower frame 230 along the first direction are connected to a plurality of vertical beams 240. The other ends of the upper frame 220 and the lower frame 230 form an opening 211 for the partition 300 to pass through. The upper frame 220, the lower frame 230 and the plurality of vertical beams 240 enclose a storage space.

[0038] In this embodiment, as Figure 2 As shown, the upper frame 220 can be a rectangular plate structure, and the lower frame 230 is also a rectangular plate structure. Both the upper frame 220 and the lower frame 230 are arranged horizontally and vertically at intervals. The upper frame 220 is located above the lower frame 230. Between the upper frame 220 and the lower frame 230, and at one end along the width direction of the fabric frame 200, there are multiple vertical beams 240. The upper frame 220, the lower frame 230 and the multiple vertical beams 240 form a rectangular space to form a partition storage space 210. In addition, a rectangular opening 211 is formed on one end of the upper frame 220 and the lower frame 230 opposite to the vertical beam 240, so that the partition 300 can be placed into the mold shell 400 from the opening 211.

[0039] In the above structure, the frame structure formed by the upper frame 220, the lower frame 230 and multiple vertical beams 240 provides a stable space for storing the partition 300, which can effectively bear the weight of the partition 300 and various forces generated during movement, ensuring that the plate frame 200 will not be deformed or damaged during operation.

[0040] In the structure of the partition release mechanism, the upper frame 220 includes a plurality of first hole groups evenly spaced along a first direction, each first hole group including a plurality of first locking holes 221 evenly spaced perpendicular to the first direction. The lower frame 230 includes a plurality of second hole groups evenly spaced along the first direction, each second hole group including a plurality of second locking holes 231 evenly spaced perpendicular to the first direction. The first locking holes 221 and the second locking holes 231 are arranged opposite to each other. The partition release mechanism includes locking groups. The locking assembly includes a locking pin 250, which is movably connected to the fabric frame 200. The locking pin 250 is movable and can exist in a locked state and a released state. In the locked state, the locking pin 250 passes through the first locking hole 221 and the second locking hole 231 in sequence to restrict the partition member 300 from passing through the opening 211. In the released state, the locking pin 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 250, which is movably connected to the fabric frame 200 and can move vertically. Multiple first hole groups are distributed along the width of the upper frame 220, and these first hole groups are evenly spaced. Each first hole group further includes multiple first locking holes 221, which are evenly spaced along the width of the upper frame 220. The structure of the lower frame 230 corresponds to that of the upper frame 220. It is also provided with a plurality of second hole groups that are evenly spaced along its own width direction. Each second hole group includes a plurality of second locking holes 231 that are evenly spaced along its own length direction. The second locking holes 231 are 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, so as to ensure that in the locked state, the locking pin 250 can pass through the first locking hole 221 and the second locking hole 231 at the same time, thereby effectively restricting the partition 300.

[0042] In the initial state, the locking pin 250 is in a locked state. At this time, the locking pin 250 passes through the first locking hole 221 and the second locking hole 231 in sequence, thereby blocking the opening 211 and effectively restricting the partition 300 from passing through the opening 211, thus limiting the movement of the partition 300. When it is necessary to release the partition 300, the locking pin 250 is moved upward in the vertical direction, thereby separating the locking pin 250 from the second locking hole 231 and releasing the blockage of the opening 211. Then, using existing technologies such as a robotic arm or manual operation, the partition 300 is placed from the partition storage space 210 through the opening 211 into the corresponding position of the mold housing 400, realizing the release of the partition 300.

[0043] By engaging the locking pin 250 with the first locking hole 221 and the second locking hole 231, the release timing and position of the partition 300 can be precisely controlled. In the locked state, the locking pin 250 can reliably restrict the movement of the partition 300, preventing the partition 300 from accidentally falling when it is not needed, thus avoiding injury to the operator and damage to the mold device and the sleeper being formed.

[0044] Specifically, the dimensions and shapes of the first locking hole 221 and the second locking hole 231 are tightly fitted to the locking pin body 250. For example, their inner diameter is slightly larger than the outer diameter of the locking pin body 250 by 0.5-1 mm to ensure that the locking pin body 250 can pass through smoothly without causing excessive wobbling. In addition, the number of the first hole group, the second hole group, and the number of the first locking hole 221 and the second locking hole 231 in each hole group are determined according to the length of the fabric frame 200 and the positioning accuracy requirements of the partition member 300.

[0045] More specifically, the upper frame 220 includes at least two first crossbeams 222 that are spaced apart from each other along a first direction, and a plurality of first support beams 223. The first support beams 223 extend along the first direction, and the plurality of first support beams 223 are evenly spaced between the two first crossbeams 222. The lower frame 230 includes at least two second crossbeams 232 that are spaced apart from each other along the first direction, and a plurality of second support beams 233. The second support beams 233 extend along the first direction, and the plurality of second support beams 233 are evenly spaced between the two second crossbeams 232. The first support beams 223 and the second support beams 233 are arranged opposite to each other. A first locking hole 221 is distributed on the first support beam 223, and a second locking hole 231 is distributed on the second support beam 233.

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

[0047] The combined structure of the first crossbeam 222 with multiple first support beams 223, and the second crossbeam 232 with multiple second support beams 233, greatly enhances the overall strength and stability of the upper frame 220 and the lower frame 230. Furthermore, this structure is relatively easy to install and connect. For example, the first crossbeam 222 and the first support beams 223, and the second crossbeam 232 and the second support beams 233, can be connected using common methods such as welding or bolting, facilitating assembly on the production site. Moreover, when a component is damaged, its relatively independent structure makes replacement relatively easy. Simultaneously, this structure effectively reduces the overall weight of the upper frame 220 and the lower frame 230, facilitating lightweight production.

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

[0049] In this embodiment, as Figure 3 As shown, the partition body 320 is a rectangular plate structure. A counterweight support rod 330 is fixed to the lower end of one end face along the thickness direction. The length direction of the counterweight support rod 330 is consistent with the length direction of the partition body 320, and the length of the counterweight support rod 330 is greater than or equal to the length of the partition body 320. This allows the counterweight support plate to effectively support the partition body 320, effectively preventing deformation of the partition body 320 and avoiding gaps between the partition body 320 and the mold shell 400, which could easily cause concrete to leak out during the pouring process. Fixing the counterweight support rod 330 to the partition body 320 makes it easier for the partition body 320 to fit and connect with the mold shell 400 when the partition 300 is released.

[0050] Specifically, the mold housing 400 is provided with multiple elastic locking pins on both sides, and the partition body 320 is provided with locking grooves at both ends along its own length direction. The elastic locking pins can be movably engaged with the locking grooves to fit and lock the partition body 320 and the mold housing 400 together.

[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. These elastic locking pins are existing technology; for example, an elastic locking pin mainly consists of a pin body, a spring, and a mounting base. One end of the pin body is a working end for insertion into the locking groove of the partition body 320. The shape of the working end matches the locking groove, and it is generally cylindrical, with a slightly tapered end for easy insertion. The other end of the pin body is connected to a spring, which is fitted onto the pin body. The mounting base is fixed to the mold housing 400 to accommodate the spring and support the pin body, ensuring a stable installation of the elastic locking pin on the mold housing 400. The partition body 320 has locking grooves at both ends along its length direction. The shape and size of the locking grooves match the working ends of the elastic locking pins to ensure smooth insertion and tight fit. After the partition plate 300 falls into the forming chamber 410, the operator slightly adjusts the position of the partition plate 300 so that the locking groove is aligned with the elastic locking pin. After the partition plate body 320 is locked to the mold housing 400, due to the tight fit between the elastic locking pin and the locking groove, the partition plate body 320 is firmly fixed to the mold housing 400. Even under the large impact force generated during concrete pouring and the strong vibration during the vibration process, the partition plate body 320 will not shift or shake, ensuring the stability of the shape and size of the sleeper forming space.

[0052] In the specific structure of the drive mechanism 500, the drive mechanism 500 includes two tracks 510 that are relatively spaced apart along a direction perpendicular to the first direction. The tracks 510 extend along the first direction, and the mold housing 400 is disposed between the two tracks 510. The drive mechanism 500 also includes a plurality of traveling wheels 520, which are evenly distributed on both sides of the fabric frame 200. The traveling wheels 520 are movably connected to the tracks 510 and can move along the tracks 510. The drive mechanism 500 includes a drive motor, and at least one set of two traveling wheels 520 in opposite positions are connected by a drive shaft. The output end of the drive motor is provided with a first transmission wheel, and the drive shaft is fixed with a second transmission wheel. The first transmission wheel and the second transmission wheel are connected in a transmission manner. The drive motor is used at least to drive the traveling wheels 520 to rotate, thereby driving the fabric frame 200 to move along the tracks 510.

[0053] In this embodiment, as Figure 2As shown, two tracks 510 are spaced apart along the width direction of the fabric frame 200, with the track 510 extending along the length direction of the production line. The mold housing 400 is positioned between the two tracks 510. Multiple traveling wheels 520 are evenly distributed on both sides along the width direction of the fabric frame 200. The number of traveling wheels 520 is rationally configured according to the length and load-bearing capacity of the fabric frame 200, generally with a set of traveling wheels 520 installed at certain intervals. The traveling wheels 520 cooperate with the tracks 510, allowing the traveling wheels 520 to move on the tracks 510. The tracks 510 provide guidance and limit functions for the traveling wheels 520, reducing friction during the movement of the fabric frame 200 and further improving the movement efficiency of the fabric frame 200. In addition, a set of traveling wheels 520 located at one end of the fabric frame 200 is connected via a drive shaft. A second transmission wheel is fixed on the drive shaft, and a first transmission wheel is mounted on the output shaft of the drive motor. The type of the first transmission wheel can be a pulley, sprocket, or gear, and the type of the second transmission wheel matches that of the first transmission wheel. When the mold device needs to be operated, the drive motor is started. After the drive motor is powered on, it starts to run, and 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 along with the rotation of the first transmission wheel. The second transmission wheel is mounted on the drive shaft, which is connected to the traveling wheels 520. Therefore, the drive shaft drives the traveling wheels 520 to rotate. Multiple traveling wheels 520 are evenly distributed on both sides of the fabric frame 200. During the rotation of the traveling wheels 520, the fabric frame 200 moves along the track 510 in the first direction.

[0054] By coordinating the drive motor, transmission wheel, and drive shaft, the rotation speed and direction of the traveling wheel 520 can be precisely controlled, ensuring that the partition 300 is accurately placed in the molding chamber 410 at predetermined intervals, thereby improving the dimensional accuracy and quality stability of the produced prestressed concrete sleepers.

[0055] Example 2

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

[0057] S1. Clean the mold shell 400, apply a release agent to the molding chamber 410, and set the mold shell 400 along the first direction.

[0058] In this step, specialized cleaning tools, such as wire brushes and vacuum cleaners, are used to remove residual concrete, dust, oil, and other impurities from the inner surface of the mold shell 400, creating a foundation for subsequent application of the release agent and concrete pouring. A suitable release agent is selected, and the appropriate application method is chosen based on the type of release agent. For oil-based release agents, a spray gun can be used; for water-based release agents, a brush can be used, ensuring a uniform coating thickness. The mold shell 400 is then placed in the pre-determined working position in the first direction (i.e., the sleeper's forming direction). Mold cleaning and release agent application ensure good separation between the concrete and the mold, effectively reducing surface defects and improving the sleeper's appearance quality.

[0059] S2. Multiple partition members 300 are stacked along a first direction in the partition storage space 210. Unstressed prestressed steel wires 100 are sequentially passed through the partition members 300. The board frame 200 is driven to move along the first direction by the drive mechanism 500. The partition members 300 are then spaced apart along the first direction in the forming chamber 410 by the partition release mechanism, dividing the forming chamber 410 into multiple sleeper forming spaces. Force is applied to the prestressed steel wires 100 to tighten them. Additionally, in S2, a wire tensioning device applies force to the prestressed steel wires 100.

[0060] In this step, multiple partition pieces 300 are stacked sequentially along the first direction within the partition storage space 210 of the fabric frame 200. During stacking, the partition pieces 300 are kept neat and stable. Unstressed prestressed steel wires 100 are passed sequentially through the through holes 310 through the multiple partition pieces 300. The drive mechanism 500 is activated, and the drive motor rotates the first transmission wheel. Power is transmitted to the second transmission wheel via a transmission belt, chain, or gear, which in turn rotates the drive shaft and the traveling wheels 520, causing the fabric frame 200 to move along the track 510 in the first direction. When the fabric frame 200 reaches a specific position, the partition release mechanism activates, placing the partition pieces 300 at intervals within the forming chamber 410, dividing the forming chamber 410 into multiple sleeper forming spaces. After the partition pieces 300 are placed, specialized steel wire tensioning equipment, such as jacks or tensioning machines, is used to apply tension to the prestressed steel wires 100, causing them to reach the predetermined tension stress value. By setting up a drive mechanism 500 and a partition release mechanism, the time for the partition component 300 to pass through the prestressed steel wire 100 and to place it is greatly shortened, thereby improving production efficiency.

[0061] S3. Pouring and Vibrating Concrete into the Sleeper Forming Spaces. In this step, the mixed concrete is slowly poured into the sleeper forming spaces separated by partitions 300 using concrete conveying equipment, such as a concrete pump truck or hopper. Simultaneously, vibration equipment, such as an immersion vibrator or a plate vibrator, is activated to vibrate the concrete, removing air from the concrete, making it more compact, and improving the strength and durability of the sleepers.

[0062] S4. After the concrete has solidified, release the prestress of the prestressed steel wire 100 and cut between two adjacent partition plates 300 in the forming spaces of two adjacent sleepers to divide it into multiple sleeper blocks. In this step, after the concrete has solidified to a certain strength, use professional prestress release equipment, such as a tensioning machine, to slowly release the prestress of the prestressed steel wire 100. Then, use cutting equipment, such as an electric saw or water jet, to cut between two adjacent partition plates 300 in the forming spaces of two adjacent sleepers to divide the whole block of concrete into multiple sleeper blocks.

[0063] S5. Demold the sleeper blocks to form sleepers, and perform appearance inspection, dimensional measurement and subsequent processing on the sleepers.

[0064] In this step, using demolding tools such as pry bars or demolding devices, the molded sleeper is carefully removed from the mold housing 400. After demolding, the sleeper undergoes a visual inspection to check for defects such as cracks, pitting, and honeycombing on the surface. Visual inspection and dimensional measurement allow for the timely detection of quality problems, facilitating quality control and adjustments to the production process.

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

Claims

1. A mold device for prestressed concrete railway sleepers, comprising prestressed steel wires, characterized in that, The system also includes a fabric plate frame, multiple partition members, and a mold housing. The mold housing extends along a first direction and has a forming chamber opening to one side. The fabric plate frame is located on the side opposite to the forming chamber and has a partition storage space. The multiple partition members are stacked in the partition storage space along the first direction. Each partition member has multiple through holes, which are correspondingly connected. The prestressed steel wires without applied force are sequentially passed through the multiple partition members through the through holes. The partition storage space is equipped with a partition release mechanism, which is at least used to place the partition members with the prestressed steel wires inserted from the partition storage space into the forming chamber. The fabric plate frame is connected to a driving mechanism, which is at least used to drive the fabric plate frame to move along the first direction, so that the partition release mechanism releases the partition members with the prestressed steel wires inserted at intervals along the first direction. The multiple partition members divide the forming chamber into multiple sleeper forming spaces.

2. The mold device for prestressed concrete railway sleepers according to claim 1, characterized in that, The fabric frame includes an upper frame and a lower frame arranged at relative intervals. One end of the upper frame along the first direction and one end of the lower frame along the first direction are connected to a plurality of vertical beams. The other ends of the upper frame and the lower frame form openings for the partition to pass through. The upper frame, the lower frame and the plurality of vertical beams enclose the storage space.

3. The mold device for prestressed concrete railway sleepers according to claim 2, characterized in that, The upper frame includes a plurality of first hole groups evenly spaced along the first direction, each first hole group including a plurality of first locking holes evenly spaced perpendicular to the first direction. The lower frame includes a plurality of second hole groups evenly spaced along the first direction, each second hole group including a plurality of second locking holes evenly spaced perpendicular to the first direction. The first locking holes and the second locking holes are arranged opposite to each other. The partition release mechanism includes a locking assembly, which includes a locking pin. The locking pin is movably connected to the fabric frame and can be in a locked state and a released state. In the locked state, the locking pin passes through the first locking hole and the second locking hole in sequence to restrict the partition from passing through the opening. In the released state, the locking pin separates from the first locking hole and the second locking hole, allowing the partition to pass through the opening.

4. The mold device for prestressed concrete railway sleepers according to claim 3, characterized in that, The upper frame includes at least two first crossbeams arranged at intervals relative to each other 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 crossbeams. The lower frame includes at least two second crossbeams arranged at intervals relative to each other 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 crossbeams. The first support beams and the second support beams are arranged opposite to each other. 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 prestressed concrete railway sleepers according to claim 1, characterized in that, The partition includes a partition body and a counterweight support rod. The partition body has multiple through holes. The counterweight support rod is fixed to one end of one side of the partition body. The counterweight support rod extends along the length of the partition body, and the length of the counterweight support rod is not less than the length of the partition body.

6. The mold device for prestressed concrete railway sleepers according to claim 5, characterized in that, The mold housing is provided with multiple elastic locking pins on both sides, and the partition body is provided with locking grooves at both ends along its own length direction. The elastic locking pins can be movably engaged with the locking grooves to fit and lock the partition body and the mold housing together.

7. The mold device for prestressed concrete railway sleepers 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, and the mold housing is disposed between the two tracks. The driving mechanism also includes a plurality of traveling wheels that are evenly distributed on both sides of the fabric frame. The traveling wheels are movably connected to the tracks and can move along the tracks.

8. The mold device for prestressed concrete railway sleepers according to claim 7, characterized in that, The driving mechanism includes a drive motor, at least one set of two walking wheels in opposite positions are connected by a drive shaft, the output end of the drive motor is provided with a first transmission wheel, the drive shaft is fixed with a second transmission wheel, the first transmission wheel and the second transmission wheel are connected in a transmission manner, and the drive motor is used to drive the walking wheels to rotate so as to drive the fabric frame to move along the track.

9. A method for forming a railway sleeper based on a mold device for prestressed concrete railway sleepers according to any one of claims 1-8, characterized in that, Includes the following steps, S1. Clean the mold shell, apply a release agent to the molding chamber, and set the mold shell along the first direction; S2. Stack multiple partition members along the first direction in the partition storage space, pass the unstressed prestressed steel wire through the multiple partition members in sequence, drive the board frame to move along the first direction through the driving mechanism, and place the partition members at intervals along the first direction in the forming chamber through the partition release mechanism to divide the forming chamber into multiple sleeper forming spaces, and apply force to the prestressed steel wire to tighten the prestressed steel wire; S3. Pour concrete into the sleeper forming space and vibrate it; S4. After the concrete has solidified, release the prestress of the prestressed steel wire and cut the two adjacent partition pieces in the two adjacent sleeper forming spaces to divide them into multiple sleeper blocks. S5. Demold the sleeper block to form a sleeper, and perform appearance inspection, size measurement and subsequent processing on the sleeper.

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

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