Shield segment production equipment and shield segment production process based on AGV transfer

Abstract

The invention belongs to the technical field of shield segment production, and discloses shield segment production equipment based on AGV transfer and a shield segment production process. The problems that traditional shield segment production equipment is complex in driving, low in transfer flexibility, insufficient in maintenance space utilization rate and high in technological manual dependence are effectively solved. The production equipment comprises a roller type transmission operation unit which is driven by a single gear motor and a chain in a linkage mode. The AGV transfer system comprises three heavy-load AGVs, and the three heavy-load AGVs all adopt a magnetic stripe navigation mode and are provided with differential steering wheel driving structures and hydraulic jacking devices. A plurality of groups of independent steam-curing modules are arranged according to a'single kiln and five molds'; and an automatic demolding device and a central control system. According to the production process, duct piece production is achieved through mold pretreatment, assembling, double-station pouring and vibrating, surface treatment, AGV transferring and static curing and finished product detecting and warehousing. The one-time detection qualified rate of finished products is 100%, and the method is suitable for large-scale automatic production of shield segments.

Description

Technical Field

[0001] This invention belongs to the field of shield tunnel segment production technology, and particularly relates to a shield tunnel segment production equipment and shield tunnel segment production process based on AGV transfer. Background Technology

[0002] As the core load-bearing component of shield tunnels, the production efficiency and quality of shield tunnel segments directly affect the project's progress and safety. Traditional production methods have many drawbacks: drive systems often use multi-motor distributed drives, resulting in complex structures and high maintenance costs; mold transfer relies on fixed track equipment, leading to poor flexibility; at the same time, redundant parameters in the concrete pouring process easily lead to complex control, and manual involvement in processes such as mold opening and cleaning results in insufficient stability of segment quality, with a first-pass yield of only about 95% for finished products. Summary of the Invention

[0003] One objective of this invention is to provide a shield tunnel segment production equipment based on AGV transfer, which effectively solves the problems of complex drive, low transfer flexibility, insufficient maintenance space utilization, and high dependence on manual labor in traditional shield tunnel segment production equipment.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a shield tunnel segment production equipment based on AGV transfer, comprising: a roller-type transmission operation unit, configured with a single set of drive components, the drive components including two reduction motors and a chain linkage mechanism, which drives the wheels to rotate through the chain; the roller-type transmission operation unit is provided with an automatic mold opening station, a demolding station, an automatic cleaning station, an automatic release agent spraying station, an automatic mold closing station, a rebar cage hoisting station, an embedded part placement station, a dual-station concrete pouring and vibration unit, a surface concrete cleaning station, and an automatic rough finishing station along the material flow direction, and a static stopping area, a curing kiln, and a finished product inspection station on the outside.

[0005] The AGV transfer system includes three heavy-duty AGVs, all of which use magnetic strip navigation and are equipped with a differential steering wheel drive structure and a hydraulic lifting device. The first heavy-duty AGV is used to transfer the mold from the end of the roller-type transmission operation unit to the static stopping area, the second heavy-duty AGV is used to transfer the mold from the static stopping area to the curing kiln, and the third heavy-duty AGV is used to transfer the mold from the curing kiln back to the roller-type transmission operation unit.

[0006] Multiple independent steam curing modules are used, each of which is divided into a curing kiln. Each curing kiln holds five tube sheet molds and is equipped with independent temperature and humidity control components and temperature and humidity sensors.

[0007] An automatic demolding device is located next to the finished product inspection station. It is used to lift the molded tube pieces in the mold after curing and transfer them to the finished product inspection station.

[0008] The central control system adopts a two-layer control architecture of PLC and industrial computer, and establishes bidirectional signal connection with roller-type transmission operation unit, AGV transfer system, independent steam curing module and automatic demolding device through industrial Ethernet.

[0009] Furthermore, the diameter of the wheel of the chain linkage mechanism of the roller transmission operation unit is 200-250mm, and the drive components of the roller transmission operation unit are distributed at intervals of 1-1.3m along the length direction of the roller transmission operation unit.

[0010] Furthermore, the differential steering wheel of the heavy-duty AGV transfer module has a stepless speed regulation function, and the steering accuracy is ≤±3mm.

[0011] Furthermore, the central control system is connected to 16 to 20 proximity sensors and RFID readers to realize mold position monitoring, type identification and full-process data traceability, and to control the magnetic strip navigation path switching and differential steering wheel operation parameters of the heavy-duty AGV in real time.

[0012] Furthermore, the dual-station concrete pouring vibration unit includes two parallel pouring vibration stations, each equipped with an independent concrete conveying mechanism and a high-frequency vibration component.

[0013] Furthermore, the central control system maintains the temperature inside the curing kiln at 50-60℃ and the relative humidity at ≥90%; at the same time, it ensures that the positioning deviation of the heavy-duty AGV on the transfer path is ≤±2mm through magnetic strip navigation signal calibration.

[0014] Another objective of this invention is to provide a shield tunnel segment production process based on AGV transfer, using the shield tunnel segment production equipment described in the above embodiments, including the following steps: S1, mold pretreatment: the mold is driven by the roller transmission operation unit to the automatic mold opening station to complete the mold opening, and then to the demolding station to take out the formed segment. The empty mold continues to flow to the automatic cleaning station to remove residual debris from the inner wall, and then to the automatic release agent spraying station to uniformly spray the release agent.

[0015] S2. Mold assembly: The pre-treated mold is transferred to the automatic mold closing station to complete the mold closing, and then passes through the steel cage hoisting station and the embedded part placement station in sequence.

[0016] S3, Concrete Pouring and Vibration: The mold enters the dual-station concrete pouring and vibration unit, and the two parallel stations simultaneously carry out concrete pouring and high-frequency vibration.

[0017] S4. Segment Surface Treatment: After the casting is completed, the mold is transferred to the surface concrete cleaning station to remove excess concrete from the surface, and then to the automatic rough troweling station for rough troweling operation to make the surface flatness error of the segment ≤2mm / m.

[0018] S5. Static Stop and Curing: The central control system issues instructions, and the first heavy-duty AGV travels along the preset path to the end of the roller-type transmission operation unit via magnetic strip navigation. After the differential steering wheel is precisely adjusted to the position, the hydraulic lifting device lifts the mold and transfers it to the static stop area. After static stop is completed, the second heavy-duty AGV transfers the mold to the curing kiln of the independent steam curing module via magnetic strip navigation and cures it according to the preset temperature and humidity curve.

[0019] S6. Finished Product Inspection and Warehousing: After curing, the third heavy-duty AGV uses magnetic strip navigation to transfer the mold back to the roller-type transmission operation unit; the automatic demolding device lifts the formed tube segments and transfers them to the finished product inspection station to inspect the surface defects (accuracy ≤0.2mm), dimensions (error within ±2mm) and concrete strength (≥50MPa) of the tube segments; qualified tube segments are put into warehousing, and unqualified tube segments are marked and reworked.

[0020] Compared with the prior art, the beneficial technical effects of the present invention are: the present invention simplifies the drive structure, the AGV transfer accuracy is high and the stability is strong, the dual-station casting shortens the production cycle, the first-time inspection pass rate of finished products is 100%, the labor cost is reduced by more than 50%, it is suitable for the production of tunnel segments with different diameters from 3 to 16m, and it is suitable for the large-scale automated production of shield tunnel segments. Detailed Implementation

[0021] Example 1: This example provides a shield tunnel segment production equipment based on AGV transfer, including: (1) a roller-type transmission operation unit, configured with a single set of drive components. The drive components include two geared motors and a chain linkage mechanism, which drives the wheels to rotate through the chain. By adopting a "single geared motor + chain linkage" drive structure, the traditional multi-motor distributed drive is replaced. The wheel diameter is 200-250mm. The drive components are distributed at intervals of 1-1.3 meters along the length direction of the roller-type transmission operation unit, which can realize the mold adjustable speed movement of 5-20m / min, with a braking error ≤±5mm. The structure is simplified while reducing maintenance costs by 40%.

[0022] The roller-driven operation unit is equipped with an automatic mold opening station, a demolding station, an automatic cleaning station, an automatic release agent spraying station, an automatic mold closing station, a steel cage hoisting station, an embedded part placement station, a dual-station concrete pouring and vibration unit, a surface concrete cleaning station, and an automatic rough finishing station along the material flow direction. On the outside, there is a static stopping area, a curing kiln, and a finished product inspection station.

[0023] The dual-station concrete pouring vibration unit includes two parallel pouring vibration stations, each equipped with an independent concrete conveying mechanism and high-frequency vibration components.

[0024] (2) The AGV transfer system includes three heavy-duty AGVs. All three heavy-duty AGVs use magnetic strip navigation (ground magnetic strip width 15-20mm), and are equipped with a differential steering wheel drive structure and a hydraulic lifting device. The left and right steering wheels of the differential steering wheel drive structure have independent speed adjustment, steering accuracy ≤±3mm, and load capacity of 20-40 tons. The lifting stroke of the hydraulic lifting device is 100-150mm. The first heavy-duty AGV is used to transfer the mold from the end of the roller-type transmission operation unit to the static stopping area, the second heavy-duty AGV is used to transfer the mold from the static stopping area to the curing kiln, and the third heavy-duty AGV is used to transfer the mold from the curing kiln back to the roller-type transmission operation unit. This avoids path intersections and congestion.

[0025] (3) Multiple independent steam curing modules are arranged in a "5 modules per kiln" layout. Each group is divided into a curing kiln, and each curing kiln holds five tube sheet molds. A 300-400mm operating space is reserved between the molds, which increases the site utilization rate by more than 60%. The curing kiln is equipped with independent temperature and humidity control components and temperature and humidity sensors, and the curing environment is precisely controlled through a central control system.

[0026] (4) Automatic demolding device, located next to the finished product inspection station, is used to lift the molded tube segments in the mold after curing and transfer them to the finished product inspection station to realize the automation of tube segment inspection and transfer.

[0027] (5) Central control system, which integrates equipment linkage, data acquisition and traceability functions to ensure full process controllability. It adopts a two-layer control architecture of PLC and industrial computer, and establishes bidirectional signal connection with roller transmission operation unit, AGV transfer system, independent steam curing module and automatic demolding device through industrial Ethernet.

[0028] The central control system is connected to 16-20 proximity sensors (positioning error ≤ ±3mm) and RFID readers (reading distance 50-80mm) to achieve mold position monitoring, type identification, and full-process data traceability (data storage period ≥ 3 years). It can also control the switching of the magnetic strip navigation path and the differential steering wheel operating parameters of the heavy-duty AGV in real time. The central control system maintains the temperature inside the curing kiln at 50-60℃ and the relative humidity at ≥ 90%; simultaneously, through magnetic strip navigation signal calibration, it ensures that the positioning deviation of the heavy-duty AGV on the transfer path is ≤ ±2mm.

[0029] In this embodiment, the main wheels of the roller-type transmission work unit are made of No. 45 steel (200mm in diameter, surface hardened), and are distributed at intervals of 1.3 meters along the length of the work unit, for a total of 65 sets of wheels; the mold moving speed is set to 10m / min, and the braking error is controlled within ±3mm.

[0030] The three heavy-duty AGVs in the AGV transfer system all use magnetic strip navigation (magnetic strip model TAPE-AGV-01, width 18mm), with a load capacity of 20-40 tons and a hydraulic lifting device that can lift 150mm. The heavy-duty AGVs are set to move at a speed of 20-40m / min, and smooth steering is achieved by using the speed difference of the differential steering wheel when turning.

[0031] The temperature and humidity control components of the independent steam curing module are a DN50 steam solenoid valve (control accuracy ±0.1MPa) and a 2kW stainless steel heating tube, and the temperature and humidity sensor is a Sensirion SHT31 series.

[0032] The automatic demolding device adopts a truss structure and is equipped with a vacuum suction cup lifting device.

[0033] The central control system uses Siemens S7-1500 PLC + WinCC V7.5 monitoring software to connect proximity sensors and RFID devices, enabling full-process data traceability.

[0034] Example 2: This example provides a shield tunnel segment production process based on AGV transportation. It adopts the shield tunnel segment production equipment described in Example 1 and is designed as a closed loop of "pre-treatment-assembly-casting-surface treatment-transfer and curing-inspection". Each link is seamlessly connected with the AGV through roller-type transmission operation unit: the pre-treatment stage completes mold cleaning and release agent spraying simultaneously; the assembly stage accurately completes the installation of steel cage and embedded parts; the dual-station casting and vibration operation is carried out in parallel to shorten the casting time; the AGV transportation realizes efficient connection across regions, and the overall production process has no manual intervention interruptions.

[0035] Specifically, it includes the following steps: S1, mold pretreatment.

[0036] Driven by the roller-type transmission unit, the mold moves to the automatic mold opening station to complete the mold opening, and then to the demolding station to remove the formed tube. The empty mold continues to move to the automatic cleaning station to remove residual debris from the inner wall, and then to the automatic release agent spraying station to evenly spray the release agent (thickness 0.1-0.2mm, in this embodiment the thickness is 0.15mm).

[0037] S2, Mold assembly.

[0038] After pretreatment, the mold is transferred to the automatic mold closing station to complete the mold closing. It then passes through the steel cage hoisting station (to accurately place the steel cage into the mold with a positioning error of ≤±5mm) and the embedded parts placement station (to install embedded parts such as waterstop strips and hoisting bolts).

[0039] S3. Concrete pouring and vibration.

[0040] The mold enters the dual-station concrete pouring and vibration unit, and C50 concrete is poured simultaneously at the two parallel stations. The high-frequency vibration component vibrates the concrete until the density is ≥98.5%.

[0041] S4. Segment surface treatment.

[0042] After the pouring is completed, the mold is transferred to the surface concrete cleaning station to remove excess concrete from the surface, and then to the automatic rough troweling station for rough troweling operation (pressure 0.4MPa) to make the surface flatness error of the segment ≤2mm / m.

[0043] S5. Static Stop and Maintenance.

[0044] The central control system issues instructions, and the first heavy-duty AGV travels along the preset path to the end of the roller-type transmission operation unit via magnetic strip navigation. After the differential steering wheel is precisely adjusted, the hydraulic lifting device lifts the mold and transfers it to the static stopping area for static stopping. After static stopping, the second heavy-duty AGV transfers the mold to the curing kiln of the independent steam curing module via magnetic strip navigation, and cures it according to the curve of "heating to 50℃-55℃ for 1 hour and holding it at a constant temperature for 4 hours - cooling down to room temperature for 1 hour".

[0045] S6. Finished product inspection and warehousing.

[0046] After curing, the third heavy-duty AGV uses magnetic strip navigation to transfer the mold back to the roller-type transmission operation unit; the automatic demolding device lifts the formed tube segments and transfers them to the finished product inspection station to inspect the surface defects (accuracy 0.15mm), dimensions (error ±1.8mm) and concrete strength (≥50MPa) of the tube segments; qualified tube segments are put into storage, and unqualified tube segments are marked and reworked.

[0047] Compared with the prior art, the present invention has the following advantages: (1) Simplified equipment structure: single geared motor and chain linkage drive reduce the number of motors by 70%, equipment maintenance costs by 40%, and transmission stability by 30%. (2) Improved transfer efficiency: magnetic strip navigation and differential steering wheel drive reduce the positioning deviation of heavy-duty AGV to ≤±2mm, making steering more flexible and shortening mold waiting time by 60%. (3) Optimized production efficiency: dual-station pouring and vibration improves the efficiency of the pouring process by 50%, and the output of single-shift pipe segments increases from the traditional 12-15 segments to 18-22 segments, improving overall production efficiency by 40%. (4) Improved space utilization: five molds are placed in a single curing kiln, compared with the traditional single kiln of 2-3 molds, increasing site utilization by 60% and saving 25% of infrastructure costs. (5) Quality and cost advantages: fully automated operation reduces manual intervention, the first-time inspection pass rate of finished products reaches 100%, labor costs are reduced by 50% (only 8-10 people / shift are needed to monitor the equipment), and curing energy consumption is reduced by 20%.

[0048] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A shield tunnel segment production equipment based on AGV transfer, characterized in that, include: The roller-type transmission operation unit is equipped with a single drive assembly, which includes two geared motors and a chain linkage mechanism, driving the wheels to rotate via the chain. Along the material flow direction, the roller-type transmission operation unit is equipped with an automatic mold opening station, a demolding station, an automatic cleaning station, an automatic release agent spraying station, an automatic mold closing station, a rebar cage hoisting station, an embedded part placement station, a dual-station concrete pouring and vibration unit, a surface concrete cleaning station, and an automatic rough finishing station. An external static stopping area, a curing kiln, and a finished product inspection station are provided. The AGV transfer system includes three heavy-duty AGVs, all of which use magnetic strip navigation and are equipped with a differential steering wheel drive structure and a hydraulic lifting device. The first heavy-duty AGV is used to transfer the mold from the end of the roller-type transmission operation unit to the static stopping area, the second heavy-duty AGV is used to transfer the mold from the static stopping area to the curing kiln, and the third heavy-duty AGV is used to transfer the mold from the curing kiln back to the roller-type transmission operation unit. Multiple independent steam curing modules, each group is divided into a curing kiln, each curing kiln holds five tube sheet molds, and the curing kiln is equipped with independent temperature and humidity control components and temperature and humidity sensors; An automatic demolding device is located next to the finished product inspection station and is used to lift the molded tube pieces in the mold after curing and transfer them to the finished product inspection station. The central control system adopts a two-layer control architecture of PLC and industrial computer, and establishes bidirectional signal connection with roller-type transmission operation unit, AGV transfer system, independent steam curing module and automatic demolding device through industrial Ethernet.

2. The shield tunnel segment production equipment based on AGV transfer according to claim 1, characterized in that, The diameter of the wheel of the chain linkage mechanism of the roller transmission operation unit is 200-250mm, and the drive components of the roller transmission operation unit are distributed at intervals of 1-1.3m along the length direction of the roller transmission operation unit.

3. The shield tunnel segment production equipment based on AGV transfer according to claim 2, characterized in that, The differential steering wheel of the heavy-duty AGV transfer module has stepless speed regulation function and steering accuracy ≤ ±3mm.

4. The shield tunnel segment production equipment based on AGV transfer according to claim 3, characterized in that, The central control system is connected to 16 to 20 proximity sensors and RFID readers to realize mold position monitoring, type identification and full-process data traceability, and to control the magnetic strip navigation path switching and differential steering wheel operation parameters of the heavy-duty AGV in real time.

5. The shield tunnel segment production equipment based on AGV transfer according to claim 4, characterized in that, The dual-station concrete pouring and vibration unit includes two parallel pouring vibration stations, each equipped with an independent concrete conveying mechanism and a high-frequency vibration component.

6. The shield tunnel segment production equipment based on AGV transfer according to claim 5, characterized in that, The central control system maintains the temperature inside the curing kiln at 50-60℃ and the relative humidity at ≥90%; at the same time, it ensures that the positioning deviation of the heavy-duty AGV on the transfer path is ≤±2mm through magnetic strip navigation signal calibration.

7. A shield tunnel segment production process based on AGV transfer, characterized in that, The shield tunnel segment production equipment according to any one of claims 1-6 includes the following steps: S1. Mold pretreatment; Driven by the roller-type transmission unit, the mold moves to the automatic mold opening station to complete the mold opening, and then to the demolding station to remove the formed tube. The empty mold continues to move to the automatic cleaning station to remove residual debris from the inner wall, and then to the automatic release agent spraying station to evenly spray the release agent. S2, Mold assembly; The pre-treated mold is transferred to the automatic mold closing station to complete the mold closing, and then passes through the steel cage hoisting station and the embedded part placement station in sequence. S3. Concrete pouring and vibration; The mold enters the dual-station concrete pouring and vibration unit, and the two parallel stations simultaneously carry out concrete pouring and high-frequency vibration. S4. Segment surface treatment; After the pouring is completed, the mold is transferred to the surface concrete cleaning station to remove excess concrete from the surface, and then to the automatic rough troweling station for rough troweling operation to ensure that the surface flatness error of the segment is ≤2mm / m. S5. Static rest and maintenance; The central control system issues instructions, and the first heavy-duty AGV travels along the preset path to the end of the roller transmission operation unit via magnetic strip navigation. After the differential steering wheel is precisely adjusted to the position, the hydraulic lifting device lifts the mold and transfers it to the static stopping area. After static stopping is completed, the second heavy-duty AGV transfers the mold to the curing kiln of the independent steam curing module via magnetic strip navigation, and cures it according to the preset temperature and humidity curve. S6. Finished product inspection and warehousing; After the curing is completed, the third heavy-duty AGV uses magnetic strip navigation to transfer the mold back to the roller-type transmission operation unit; the automatic demolding device lifts the formed pipe segments and transfers them to the finished product inspection station to inspect the surface defects, dimensional errors and concrete strength of the pipe segments; qualified pipe segments are put into storage, and unqualified pipe segments are marked and reworked.