Production process of subway tunnel segment
By dividing the subway tunnel pipe sheet production process into multiple workstations and using cranes to transmit, the problem of incoherent steps in traditional production methods is solved, efficient and stable assembly line production is achieved, cost reduction and quality improvement.
Patent Information
- Application Number
- CN202510531224.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-25
- Publication Date
- 2025-08-19
- Estimated Expiration
- Not applicable · inactive patent
AI Technical Summary
The production steps of traditional subway tunnel pipe segment production methods are not coherent enough, resulting in low production efficiency, high cost and unstable quality, and mold cleaning and maintenance interrupting the production process.
The production process is divided into eleven stations, and the crane is used to transmit between the stations. The mold is blown by compressed air and the mold is cleaned, and the mold release agent is added, the steel cage assembly, embedded parts installation, quality inspection and other steps are formed to form a circulating flow production line.
The production consistency and stability are achieved, the production area is reduced, the cost is reduced, and the pipe sheet quality and production efficiency are improved.
Smart Images
Figure CN120503313A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of subway tunnel segments, and in particular to a production process for subway tunnel segments. Background Art
[0002] Subway tunnel segments are key components in shield tunnel construction. They serve as the tunnel's innermost barrier, resisting soil pressure, groundwater pressure, and other special loads. Subway tunnel segments are typically made of high-strength, impermeable concrete to ensure reliable load-bearing and waterproof properties.
[0003] At present, the traditional production method of subway tunnel segments usually adopts mold casting. During operation, it is necessary to close the mold first, then pour concrete into the mold, and vibrate the mold at the same time until the concrete in the mold is completely filled and there are no bubbles. The concrete surface is then treated. After the concrete reaches sufficient strength, the surface is plastered. After the concrete solidifies, the mold is opened for finishing and finally demolding is performed to make the finished segment.
[0004] The traditional production method of subway tunnel segments is adopted, and the various production steps are not consistent enough. In addition, the mold needs to be cleaned and maintained after use before it can be used next time, which will cause the entire production process to be interrupted. In addition, the mold needs to be transported by a cart throughout the entire production process, which is time-consuming and labor-intensive, resulting in low production efficiency, high production costs, and unstable quality. Summary of the Invention
[0005] The purpose of the present invention is to provide a production process for subway tunnel segments in order to solve the above-mentioned problems.
[0006] The present invention achieves the above-mentioned object through the following technical solutions. A production process for subway tunnel segments comprises the following steps: 1) Workstation division: The entire production line is divided into segment demoulding, mold cleaning, release agent application, reinforcement cage placement, embedded parts installation, quality inspection, concrete pouring, finishing, exterior cleaning, natural curing, and segment finishing. Cranes are installed between each workstation. 2) Segment demoulding: First, remove the fixing bolts of the side mold and end mold of the mold in the prescribed order, then remove the side mold and end mold, and open the mold. Then, use the crane's lifting device to clamp the segment and lift the segment from the mold. Then, place it in the segment storage area. Finally, use the crane's lifting device to clamp the mold and place it in the mold cleaning station. 3) Mold cleaning: Use compressed air to clean the mold after step 2). After cleaning, close the mold end and tighten it with the fixing bolts. 4) Applying release agent: Use the crane's lifting device to hold the mold treated in step 3) and place it at the release agent application station. Use a sprayer to evenly spray the inner surface of the mold with the release agent. 5) Lowering the steel cage: Use the crane's lifting device to clamp the mold processed in step 4) and place it on the lower steel cage station. Then, use the crane's lifting device to clamp the steel cage and lift it into the mold. 6) Install embedded parts: Use the crane's lifting device to clamp the mold processed in step 5) and place it at the embedded parts installation station. First, assemble all embedded parts in the segment, then close the mold side mold and tighten it with fixing bolts. 7) Quality Inspection: The mold processed in step 6) is clamped by a crane and placed at a quality inspection station. The mold's work quality is inspected and confirmed, and unqualified products are removed. 8) Concrete pouring: The mold that has passed the inspection in step 7) is clamped by the crane's lifting device and placed at the concrete pouring station, where it enters the pouring vibration chamber. During operation, the mold is first lifted by the vibrating table, and then the concrete is lifted into the aggregate hopper by the concrete lifting device. The concrete is then poured into the mold, and the vibrating table is started to vibrate until the pouring is completed and then stopped; 9) Surface treatment: Use the crane's lifting device to clamp the mold after step 8) and place it on the surface treatment station. Then, perform surface treatment, use a ruler to press and grind back and forth to remove excess concrete, and then cover with film to retain water. 10) Appearance cleaning: Use the crane's lifting device to clamp the mold after step 9), place the mold in the appearance cleaning station, and then use cleaning tools to clean the surface of the mold; 11) Natural curing: Use the crane's lifting device to clamp the mold treated in step 10) and place it in the natural curing station to ensure that the concrete is completely solidified; 12) Segment finishing: The mold processed in step 11) is clamped by the crane's lifting device and placed at the segment finishing station. First, the fixing bolts of the side mold and end mold are removed, and then the side mold and end mold are removed and the mold is opened. Then the surface of the segment is finished to make the finished segment. Finally, the mold is clamped by the crane's lifting device and placed at the segment demoulding station.
[0007] As a further configuration of the present invention, the sling includes a bracket, a connecting arm is provided on the bracket, and a clamp and a driving mechanism for driving the clamp to open or close are provided on the connecting arm.
[0008] As a further configuration of the present invention, the clamp includes two clamping arms, each of which includes two clamping jaws and a power mechanism for driving the two clamping jaws to open or close.
[0009] As a further configuration of the present invention, the clamping claws include a fixed frame and a clamping rod slidably connected to the fixed frame, the clamping rod is provided with a hook claw, and the fixed frame is provided with a lifting mechanism connected to the clamping rod, and the lifting mechanism is used to drive the clamping rod to move up and down.
[0010] As a further configuration of the present invention, the lifting mechanism includes a first motor arranged on a fixed frame, a first screw rod is connected to the output end of the first motor, a first nut is threadedly connected to the first screw rod, and the first nut is connected to the clamping rod.
[0011] As a further configuration of the present invention, the clamping arm includes a first support beam, two first sliding seats are slidably connected to the first support beam, the fixed frame is fixedly connected to the first sliding seat, and the power mechanism includes two oppositely arranged second motors, the output ends of the second motors are connected to second screw rods, the second screw rods are threaded with second nuts, and the second nut is connected to the first sliding seat.
[0012] As a further configuration of the present invention, the clamp includes a second support beam, two second sliding seats are slidably connected to the second support beam, the first support beam is fixedly connected to the second sliding seat, and the driving mechanism includes two relatively arranged third motors, the output ends of the third motors are connected to third screw rods, the third screw rods are threaded with third nut, and the third nut is connected to the second sliding seat.
[0013] As a further configuration of the present invention, the clamping rod and the hook claw are both made of stainless steel.
[0014] In summary, the present invention has the following beneficial effects: The present invention divides each step into eleven workstations for operation, and realizes the transmission between each workstation through a crane. The operation is convenient and labor-saving, thereby forming a circulating assembly line. After the previous step is completed, it can quickly enter the next step. The various production steps have good continuity and compact connection. The steps of mold cleaning and appearance cleaning are added to the production process of the pipe segment to avoid interruption of the production process and ensure the continuity of production. Moreover, since assembly line production is adopted, the entire production environment can be carried out in one area, so that the production conditions of the pipe segment tend to be consistent, and the area of the production area is reduced, which is not only convenient for management, but also effectively reduces production costs, thereby ensuring the quality and stability of the pipe segment. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Figure 1It is a structural schematic diagram of the sling in the present invention; Figure 2 for Figure 1 Schematic diagram of the enlarged structure at point A in the middle.
[0016] Figure numerals: 1. bracket; 2. connecting arm; 3. fixing frame; 4. clamping rod; 5. hook; 6. first motor; 7. first screw rod; 8. first nut; 9. first support beam; 10. first sliding seat; 11. second motor; 12. second screw rod; 13. second nut; 14. second support beam; 15. second sliding seat; 16. third motor; 17. third screw rod; 18. third nut. DETAILED DESCRIPTION
[0017] The following is a clear and complete description of the technical solutions in the embodiments of the present invention. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts are within the scope of protection of the present invention.
[0018] A production process for subway tunnel segments, comprising the following steps: 1) Workstation division: The entire production line is divided into segment demoulding, mold cleaning, release agent application, reinforcement cage placement, embedded parts installation, quality inspection, concrete pouring, finishing, exterior cleaning, natural curing, and segment finishing. Cranes are installed between each workstation. 2) Segment demoulding: First, remove the fixing bolts of the side mold and end mold of the mold in the prescribed order, then remove the side mold and end mold, and open the mold. Then, use the crane's lifting device to clamp the segment and lift the segment from the mold. Then, place it in the segment storage area. Finally, use the crane's lifting device to clamp the mold and place it in the mold cleaning station. 3) Mold cleaning: Use compressed air to clean the mold after step 2). After cleaning, close the mold end and tighten it with the fixing bolts. 4) Applying release agent: Use the crane's lifting device to hold the mold treated in step 3) and place it at the release agent application station. Use a sprayer to evenly spray the inner surface of the mold with the release agent. 5) Lowering the steel cage: Use the crane's lifting device to clamp the mold processed in step 4) and place it on the lower steel cage station. Then, use the crane's lifting device to clamp the steel cage and lift it into the mold. 6) Install embedded parts: Use the crane's lifting device to clamp the mold processed in step 5) and place it at the embedded parts installation station. First, assemble all embedded parts in the segment, then close the mold side mold and tighten it with fixing bolts. 7) Quality Inspection: The mold processed in step 6) is clamped by a crane and placed at a quality inspection station. The mold's work quality is inspected and confirmed, and unqualified products are removed. 8) Concrete pouring: The mold that has passed the inspection in step 7) is clamped by the crane's lifting device and placed at the concrete pouring station, where it enters the pouring vibration chamber. During operation, the mold is first lifted by the vibrating table, and then the concrete is lifted into the aggregate hopper by the concrete lifting device. The concrete is then poured into the mold, and the vibrating table is started to vibrate until the pouring is completed and then stopped; 9) Surface treatment: Use the crane's lifting device to clamp the mold after step 8) and place it on the surface treatment station. Then, perform surface treatment, use a ruler to press and grind back and forth to remove excess concrete, and then cover with film to retain water. 10) Appearance cleaning: Use the crane's lifting device to clamp the mold after step 9), place the mold in the appearance cleaning station, and then use cleaning tools to clean the surface of the mold; 11) Natural curing: Use the crane's lifting device to clamp the mold treated in step 10) and place it in the natural curing station to ensure that the concrete is completely solidified; 12) Segment finishing: The mold processed in step 11) is clamped by the crane's lifting device and placed at the segment finishing station. First, the fixing bolts of the side mold and end mold are removed, and then the side mold and end mold are removed and the mold is opened. Then the surface of the segment is finished to make the finished segment. Finally, the mold is clamped by the crane's lifting device and placed at the segment demoulding station.
[0019] The present invention adopts a production process flow of dividing work stations, demoulding the pipe segments, cleaning the molds, applying the release agent, placing the steel cage, installing the embedded parts, quality inspection, pouring concrete, plastering treatment, appearance cleaning, natural maintenance, and pipe segment finishing. The various steps are divided into eleven work stations for operation, and the transmission between the various work stations is achieved by a crane. The operation is relatively convenient and labor-saving, thereby forming a circulating assembly line. After the previous step is completed, the next step can be quickly entered. The various production steps have good consistency and compact connection. The steps of mold cleaning and appearance cleaning are added to the production process of the pipe segments to avoid interruption of the production process and ensure the continuity of production. Moreover, due to the use of assembly line production, the entire production environment can be carried out in one area, so that the production conditions of the pipe segments tend to be consistent, and the area of the production area is reduced, which is convenient for management and effectively reduces production costs, thereby ensuring the quality and stability of the pipe segments.
[0020] See also Figure 1 As shown, the sling includes a bracket 1, a connecting arm 2 is provided on the bracket 1, and a clamp and a driving mechanism for driving the clamp to open or close are provided on the connecting arm 2. The sling can be installed on the crane by fixing the bracket 1 to the crane. When lifting is required, the clamp can be driven to open by the driving mechanism, and the object can be placed in the clamp. The clamp can then be driven to close by the driving mechanism to achieve clamping, and then the object can be lifted by the crane. The operation is relatively convenient and simple, and the transportation efficiency is high.
[0021] See also Figure 1 、 Figure 2 As shown, the clamp includes two clamping arms, each of which includes two clamping claws and a power mechanism for driving the two clamping claws to open or close, so that the clamping arms and the clamping claws can be opened and closed freely, so that the clamp can be suitable for clamping objects of different specifications, thereby improving the applicability of the sling. The clamping claws include a fixed frame 3 and a clamping rod 4 slidably connected to the fixed frame 3, and a hook 5 is provided on the clamping rod 4. The clamping rod 4 is driven up and down by the lifting mechanism to drive the hook 5 to move accordingly, so that the length of the clamping claw can be adjusted, thereby improving the applicability of the clamping claw. The clamping rod 4 and the hook 5 are both made of stainless steel with high strength and hardness. , and corrosion-resistant, so that the clamping rod 4 and the hook claw 5 have good durability, and a lifting mechanism connected to the clamping rod 4 is provided on the fixed frame 3, and the lifting mechanism is used to drive the clamping rod 4 to move up and down, wherein the lifting mechanism includes a first motor 6 arranged on the fixed frame 3, and a first screw rod 7 is connected to the output end of the first motor 6, and a first nut 8 is threadedly connected to the first screw rod 7. The first nut 8 is connected to the clamping rod 4. By starting the first motor 6, the first screw rod 7 is driven to rotate, and the first nut 8 can be driven to move along the length direction of the first screw rod 7, thereby driving the clamping rod 4 to move up and down, which is convenient to operate and has high efficiency.
[0022] See also Figure 1 、 Figure 2As shown, the clamping arm includes a first support beam 9, on which two first sliding seats 10 are slidably connected, and the fixing frame 3 is fixedly connected to the first sliding seat 10, and the power mechanism includes two second motors 11 arranged opposite to each other, and the output end of the second motor 11 is connected to a second screw rod 12, and the second screw rod 12 is threadedly connected to a second nut 13, and the second nut 13 is connected to the first sliding seat 10. By starting the second motor 11, the second screw rod 12 is driven to rotate, and the second nut 13 can be driven to move along the length direction of the second screw rod 12, thereby driving the first sliding seat 10 to slide on the first support beam 9, thereby realizing the opening and closing of the two clamping jaws, which is easy to operate and clamps. The tool includes a second support beam 14, on which two second sliding seats 15 are slidably connected, and the first support beam 9 is fixedly connected to the second sliding seat 15. The driving mechanism includes two relatively arranged third motors 16, and the output ends of the third motors 16 are connected to third screw rods 17, and the third nut 18 is threadedly connected to the third screw rod 17. The third nut 18 is connected to the second sliding seat 15. By starting the third motor 16, the third screw rod 17 is driven to rotate, and the third nut 18 can be driven to move along the length direction of the third screw rod 17, thereby driving the second sliding seat 15 to slide on the second support beam 14, thereby realizing the opening and closing of the two clamping arms, which is easy to operate.
[0023] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.
Claims
1. A production process for subway tunnel segments, characterized by: The steps include: 1) Workstation division: The entire production line is divided into segment demoulding, mold cleaning, release agent application, reinforcement cage placement, embedded parts installation, quality inspection, concrete pouring, finishing, exterior cleaning, natural curing, and segment finishing. Cranes are installed between each workstation. 2) Segment demoulding: First, remove the fixing bolts of the side mold and end mold of the mold in the prescribed order, then remove the side mold and end mold, and open the mold. Then, use the crane's lifting device to clamp the segment and lift the segment from the mold. Then, place it in the segment storage area. Finally, use the crane's lifting device to clamp the mold and place it in the mold cleaning station. 3) Mold cleaning: Use compressed air to clean the mold after step 2). After cleaning, close the mold end and tighten it with the fixing bolts. 4) Applying release agent: Use the crane's lifting device to hold the mold treated in step 3) and place it at the release agent application station. Use a sprayer to evenly spray the inner surface of the mold with the release agent. 5) Lowering the steel cage: Use the crane's lifting device to clamp the mold processed in step 4) and place it on the lower steel cage station. Then, use the crane's lifting device to clamp the steel cage and lift it into the mold. 6) Install embedded parts: Use the crane's lifting device to clamp the mold processed in step 5) and place it at the embedded parts installation station. First, assemble all embedded parts in the segment, then close the mold side mold and tighten it with fixing bolts. 7) Quality Inspection: The mold processed in step 6) is clamped by a crane and placed at a quality inspection station. The mold's work quality is inspected and confirmed, and unqualified products are removed. 8) Concrete pouring: The mold that has passed the inspection in step 7) is clamped by the crane's lifting device and placed at the concrete pouring station, where it enters the pouring vibration chamber. During operation, the mold is first lifted by the vibrating table, and then the concrete is lifted into the aggregate hopper by the concrete lifting device. The concrete is then poured into the mold, and the vibrating table is started to vibrate until the pouring is completed and then stopped; 9) Surface treatment: Use the crane's lifting device to clamp the mold after step 8) and place it on the surface treatment station. Then, perform surface treatment, use a ruler to press and grind back and forth to remove excess concrete, and then cover with film to retain water. 10) Appearance cleaning: Use the crane's lifting device to clamp the mold after step 9), place the mold in the appearance cleaning station, and then use cleaning tools to clean the surface of the mold; 11) Natural curing: Use the crane's lifting device to clamp the mold treated in step 10) and place it in the natural curing station to ensure that the concrete is completely solidified; 12) Segment finishing: The mold processed in step 11) is clamped by the crane's lifting device and placed at the segment finishing station. First, the fixing bolts of the side mold and end mold are removed, and then the side mold and end mold are removed and the mold is opened. Then the surface of the segment is finished to make the finished segment. Finally, the mold is clamped by the crane's lifting device and placed at the segment demoulding station.
2. The production process for subway tunnel segments according to claim 1, characterized in that: The sling comprises a bracket (1), a connecting arm (2) is provided on the bracket (1), and a clamp and a driving mechanism for driving the clamp to open or close are provided on the connecting arm (2).
3. The production process for subway tunnel segments according to claim 2, characterized in that: The clamp comprises two clamping arms, each of which comprises two clamping jaws and a power mechanism for driving the two clamping jaws to open or close.
4. The production process for subway tunnel segments according to claim 3, characterized in that: The clamping claws each comprise a fixing frame (3) and a clamping rod (4) slidably connected to the fixing frame (3); a hook (5) is provided on the clamping rod (4); and a lifting mechanism connected to the clamping rod (4) is provided on the fixing frame (3); the lifting mechanism is used to drive the clamping rod (4) to move up and down.
5. The production process for subway tunnel segments according to claim 4, characterized in that: The lifting mechanism comprises a first motor (6) arranged on a fixing frame (3); a first screw rod (7) is connected to an output end of the first motor (6); a first nut (8) is threadedly connected to the first screw rod (7); and the first nut (8) is connected to the clamping rod (4).
6. The production process for subway tunnel segments according to claim 4, characterized in that: The clamping arm includes a first support beam (9), two first sliding seats (10) are slidably connected to the first support beam (9), the fixing frame (3) is fixedly connected to the first sliding seat (10), and the power mechanism includes two second motors (11) arranged opposite to each other, the output ends of the second motors (11) are connected to second screw rods (12), the second screw rods (12) are threadedly connected to second nuts (13), and the second nuts (13) are connected to the first sliding seats (10).
7. The production process for subway tunnel segments according to claim 6, characterized in that: The clamp includes a second support beam (14), two second sliding seats (15) are slidably connected to the second support beam (14), the first support beam (9) is fixedly connected to the second sliding seat (15), and the driving mechanism includes two third motors (16) arranged opposite to each other, the output ends of the third motors (16) are connected to third screw rods (17), the third screw rods (17) are threadedly connected to a third nut (18), and the third nut (18) is connected to the second sliding seat (15).
8. The production process for subway tunnel segments according to claim 4, characterized in that: The clamping rod (4) and the hook claw (5) are both made of stainless steel.