Subway track plate independent kiln production line and production method
By designing an independent kiln production line for subway track slabs, the problems of disturbance caused by mold movement within the kiln and the need for fixed cycle time were solved, enabling efficient, flexible, and environmentally friendly track slab production, and improving production efficiency and quality consistency.
Patent Information
- Application Number
- CN202610028515.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-09
- Publication Date
- 2026-02-27
AI Technical Summary
Traditional track slab production methods suffer from insufficient organizational flexibility due to disturbances caused by the movement of molds within the curing kiln and a fixed production cycle.
The subway track slab independent kiln production line includes a casting line module, a handling module, a track module, multiple independent curing kiln modules, and an intelligent control module. Through step-by-step conveying and automated handling by mother-daughter trolleys, the molds are statically cured inside the kiln, and the intelligent control system coordinates the production process.
It achieves full-process automation, increases production efficiency by 100%, reduces disturbance through static mold maintenance, ensures internal quality and appearance consistency, and has high production flexibility and energy-saving and environmental protection benefits.
Smart Images
Figure CN121572437A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of rail transit prefabricated component production, and in particular to a subway track slab independent kiln production line and production method. BACKGROUND
[0002] With the rapid development of urban rail transit, the demand for subway track slabs is increasing, and the quality requirements are becoming higher and higher. The traditional track slab production mostly adopts the fixed pedestal method, and the mold completes all processes such as mold cleaning, pouring, curing, demolding, etc. on the fixed pedestal.
[0003] Although there are attempts at assembly line production in the prior art, continuous curing kilns are mostly used, the mold moves in the kiln, the disturbance to the concrete is large, and the production rhythm is fixed, which lacks flexibility in organization. SUMMARY
[0004] The purpose of the present application is to provide a subway track slab independent kiln production line and production method, which solves the problems of disturbance caused by moving the mold in the curing kiln in the traditional track slab production method, and the lack of flexibility in organization caused by the fixed production rhythm.
[0005] To achieve the above purpose, the present application provides a subway track slab independent kiln production line, which comprises a pouring line module, a carrying module, a track module, a plurality of curing kiln modules and an intelligent control module, The pouring line module is an automatic conveying line, the front end of which is provided with a demolding station, and the rear end is connected with the track module. The pouring line module is provided with a mold cleaning station, a demolding agent spraying station, a steel cage and a pre-embedded part installation station, and a concrete pouring and vibrating station along its conveying direction in sequence. The demolding station is used to take out the track slab that has completed curing from the mold, and the empty mold after demolding enters the subsequent process cycle of the pouring line module. The carrying module is used to transfer the mold between the rear end of the pouring line module, each curing kiln module and the demolding station. The track module provides a walking path for the carrying module, and the track module is connected with the end of the pouring line module, the entrances and exits of each curing kiln module and the demolding station. Each of the curing kiln modules is a closed curing unit that can be independently started and stopped and independently controlled. The intelligent control module is in communication connection with the pouring line module, the carrying module, the track module and each curing kiln module, and is used to coordinate the production process, control the carrying scheduling and monitor the curing parameters.
[0006] The pouring line module is in a straight line type or a ring type layout, and a hydraulic or electric propulsion system is used to realize step-by-step conveying of the mold.
[0007] The carrying module comprises at least two independently operated sub-trolley, wherein the first trolley is used for carrying the mold after pouring and vibrating from the pouring line module to the idle curing kiln module, and the second trolley is used for carrying the mold after curing from the curing kiln module to the demolding station.
[0008] The sub-trolley is provided with lifting and transverse moving functions, and can walk on the track module to automatically grab, transport and place the mold.
[0009] Each curing kiln module is provided with an independent kiln door, a steam pipeline, a temperature and humidity sensor and a controller, and can realize independent opening and closing and curing program control.
[0010] The intelligent control module comprises a central control unit, a man-machine interface and a data server; the intelligent control module is connected with the pouring line module, the carrying module, the track module and each curing kiln module in communication through an industrial bus or a wireless network, so as to realize automatic control and data tracing in the whole production process.
[0011] On the other hand, the application also comprises a subway track slab production method, comprising the following steps: The empty mold after demolding automatically flows on the pouring line module, and sequentially passes through a mold cleaning station and a demolding agent spraying station to perform cleaning and demolding agent spraying operations; At the steel reinforcement cage and embedded part installation station, the steel reinforcement cage, the fastener sleeve and the lifting sleeve are installed and fixed in the mold; At the concrete pouring and vibrating station, concrete is layered and laid and vibrated; The mold after vibrating is statically cured for a predetermined time, and the first sub-trolley in the carrying module carries the mold from the end of the pouring line module to an idle curing kiln module; The kiln door of the curing kiln module is closed, independent steam curing is performed according to a preset curing system, and the mold is kept stationary in the kiln during the curing; After the curing is completed, the second sub-trolley in the carrying module carries the mold from the curing kiln module to the demolding station to perform track slab demolding; The track slab after demolding is subjected to subsequent curing.
[0012] This invention discloses an independent kiln production line and method for subway track slabs. By integrating the demolding station at the front end of the casting line module, and using this as the starting and ending point of the production cycle, a closed, automated production line is constructed. After demolding, cleaning, spraying, reinforcement placement, casting, and vibration, the mold is transported by a dedicated mother-and-daughter cart system into an idle, independent curing kiln module for precise static steam curing. During this process, the mold remains fixed from kiln entry to exit, completely avoiding disturbance caused by movement. After curing, another mother-and-daughter cart precisely returns the mold to the demolding station.
[0013] The advantages of this invention are: 1. Full-process automation and high efficiency: Through automatic flow of the gating line and automatic transport of mother and daughter carts, the entire process from mold cleaning to demolding is automated, with a production cycle of 10 minutes per piece, which is 100% more efficient than the traditional pedestal method (about 20 minutes per piece).
[0014] 2. Independent kiln for precise curing, resulting in superior quality: Using independent curing kilns, the mold remains stationary from the moment it enters the kiln until curing is complete, greatly minimizing disturbance to the concrete. Each kiln has independent temperature and humidity control, ensuring more precise execution of the curing process and guaranteeing the internal quality and consistent appearance of the track slabs.
[0015] 3. High production flexibility: Through the intelligent control system, the flow rate and the number of curing kilns can be flexibly adjusted to realize multiple production organization modes, which can not only meet the needs of full-load high-efficiency production, but also adapt to the production needs of small batch or commissioning period, with high resource utilization.
[0016] 4. Modular Integration and Intelligent Control: Each process is modularly integrated on the production line, coordinating operations and reducing manual intervention. The intelligent control center enables full-process monitoring and data traceability, improving the level of precision in quality management.
[0017] 5. Significant energy-saving and environmental benefits: Compared to continuous curing in a large space, independent kiln curing reduces steam consumption and heat loss. Enclosed vibration reduces noise pollution. Overall, it reduces energy consumption and carbon emissions. Attached Figure Description
[0018] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.
[0019] Figure 1 This is a schematic diagram of the independent kiln production line for subway track slabs according to the present invention.
[0020] Figure 2 This is a flowchart of the subway track slab production method of the present invention.
[0021] In the diagram: 101-pouring line module, 102-transportation module, 103-track module, 104-curing kiln module, 105-intelligent control module, 106-demolding station, 107-mother and daughter carts. Detailed Implementation
[0022] The embodiments of the present invention are described in detail below. Examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, but should not be construed as limiting the present invention.
[0023] Please see Figure 1 ,in Figure 1 This is a schematic diagram of the independent kiln production line for subway track slabs.
[0024] This invention provides an independent kiln production line for subway track slabs, comprising a casting line module 101, a handling module 102, a track module 103, multiple curing kiln modules 104, and an intelligent control module 105. By combining front-end demolding, a continuous casting layout, an independent static curing kiln group, and a dual-vehicle automatic handling scheduling system, it solves the technical problems of component disturbance caused by mold movement within the kiln in traditional production lines, and the difficulty in flexibly adjusting production capacity due to the fixed cycle time of continuous production lines. It is understood that the aforementioned solution is suitable for manufacturing scenarios of prefabricated rail transit components (such as track slabs and sleepers) that require high dimensional accuracy and consistency of internal quality, and need to adapt to order fluctuations and achieve flexible and intelligent production.
[0025] In this specific embodiment, the pouring line module 101 is an automated conveyor line with a demolding station 106 at its front end and a track module 103 at its rear end. The pouring line module 101 is provided with a mold cleaning station, a release agent spraying station, a steel cage and embedded part installation station, and a concrete pouring and vibration station in sequence along its conveying direction. The demolding station 106 is used to remove the cured track plate from the mold, and the empty mold after demolding enters the subsequent process cycle of the casting line module 101. The transport module 102 is used to transfer molds between the rear end of the casting line module 101, each curing kiln module 104 and the demolding station 106. The track module 103 provides a walking path for the transport module 102. The track module 103 connects the end of the casting line module 101, the inlet and outlet of each curing kiln module 104, and the demolding station 106. Each of the curing kiln modules 104 is a closed curing unit that can be independently opened and closed and whose curing parameters can be independently adjusted; The intelligent control module 105 is communicatively connected to the casting line module 101, the handling module 102, the track module 103, and each curing kiln module 104, and is used to coordinate the production process, control the handling schedule, and monitor the curing parameters.
[0026] In this embodiment, the casting line module 101 is arranged in a straight line or a ring (the figure shows a straight line). A hydraulic or electric propulsion system is used to achieve step-by-step transfer of the mold, ensuring accurate positioning and stable transfer of the mold at each station. The mold cleaning station can be equipped with an automatic cleaning and vacuum adsorption device, and the release agent spraying station uses an automatic spraying robotic arm to ensure uniformity and consistency of cleaning and coating. The casting line module 101 serves as the main line for process execution. Its front-end demolding station 106 initiates the demolding of the track slab and the circulation of empty molds. Each station on the casting line module 101 sequentially completes mold cleaning, release agent spraying, installation of the reinforcing cage and embedded parts, and concrete pouring and vibration operations. The track module 103 provides a connection between the casting line module 101 and the transport module 102. The system comprises: a network of walking paths at the end of the casting line module 101, the inlet and outlet of each curing kiln module 104, and the demolding station 106; a transport module 102 utilizing at least two mother-daughter carts 107 running on the track module 103 to automatically transfer molds between the end of the casting line module 101 and each curing kiln module 104, and between each curing kiln module 104 and the demolding station 106; each curing kiln module 104, as an independently openable and controllable closed unit, receives molds delivered by the transport module 102 and performs static independent steam curing; and an intelligent control module 105 communicating with all the above modules to centrally implement production process coordination, transport scheduling control, and curing parameter monitoring of each curing kiln module 104, thereby achieving fully automated, rhythmic, and flexible production.
[0027] The transport module 102 includes at least two independently operating mother-daughter vehicles 107. The first vehicle is used to transport the mold after pouring and vibration from the pouring line module 101 to the idle curing kiln module 104, and the second vehicle is used to transport the mold after curing from the curing kiln module 104 back to the demolding station 106.
[0028] Secondly, the mother-daughter vehicle 107 has lifting and lateral movement functions, and can travel on the track module 103 to automatically grab, transfer and place molds.
[0029] Meanwhile, each curing kiln module 104 is equipped with an independent kiln door, steam pipeline, temperature and humidity sensor, and controller, enabling independent start-up and shutdown and curing program control. Each curing kiln can accommodate 4 sets of molds, and each curing kiln performs steam curing independently without interfering with each other. Once the molds are placed in the kiln, they will not be moved until the curing is completed.
[0030] In addition, the intelligent control module 105 includes a central control unit, a human-machine interface, and a data server. The intelligent control module 105 communicates with the casting line module 101, the handling module 102, the track module 103, and each curing kiln module 104 via an industrial bus or wireless network to realize automated control and data traceability of the entire production process. It includes casting line cycle control, mother-daughter car 107 scheduling, curing kiln group start-up and shutdown and curing parameter monitoring, and can flexibly adjust resource allocation according to the production plan to support the flexible operation of the production line.
[0031] In the independent kiln production line for subway track slabs of the present invention, after demolding, the empty molds undergo cleaning, spraying, installation of reinforcing bars and embedded parts, and concrete pouring and vibration on the casting line module 101 in sequence. After vibration, the molds are transported from the end of the casting line to an empty independent curing kiln module 104 by the first mother-daughter car 107. When a single curing kiln is full of molds, the kiln door is closed, and independent steam curing is carried out according to the preset "static stop, heating up, constant temperature, cooling down" curve. During this process, the molds remain stationary in the kiln, eliminating movement and disturbance. After curing, the molds are precisely transported from the curing kiln back to the demolding station 106 by the second mother-daughter car 107, completing the demolding of the track slab, and the empty molds re-enter the cycle. After demolding, the track slabs are temperature measured and then placed in a water curing tank for curing for no less than 7 days. Afterward, they are transferred to the storage yard for side-standing stacking and sprayed with moisture. The entire process is centrally coordinated, scheduled, and monitored by the intelligent control module 105. By controlling the pouring rhythm, transport path, number of independent curing kilns and curing parameters, the production rhythm is adjustable and the production organization is flexible. This significantly improves production efficiency and resource utilization while ensuring high quality and precision of components.
[0032] On the other hand, please see Figure 2 , Figure 2 This is a flowchart of the subway track slab production method of the present invention.
[0033] A method for producing subway track slabs includes the following steps: S1: The empty mold after demolding automatically flows on the gating line module, passing through the mold cleaning station and the mold release agent spraying station in sequence to perform cleaning and mold release agent spraying operations; S2: At the installation station of the steel cage and embedded parts, install and fix the steel cage, fastener sleeve and lifting sleeve into the mold; S3: At the concrete pouring and vibration station, concrete is layered and vibrated. S4: After the mold has been vibrated and cured for a predetermined time, it is transported from the end of the casting line module to an empty curing kiln module by the first mother-daughter cart in the transport module. S5: Close the kiln door of this curing kiln module and carry out independent steam curing according to the preset curing system. During the curing period, the mold remains stationary inside the kiln. S6: After curing is completed, the second mother-daughter trolley in the transport module will transport the mold from the curing kiln module back to the demolding station for demolding of the track plate; S7: After demolding, the track slab undergoes subsequent curing. The above-disclosed embodiments are merely one or more preferred embodiments of this application and should not be construed as limiting the scope of this application. Those skilled in the art can understand that implementing all or part of the above embodiments and making equivalent changes in accordance with the claims of this application still fall within the scope of this application.
Claims
1. A subway track slab independent kiln production line, characterized in that, It includes a pouring line module, a handling module, a track module, multiple curing kiln modules, and an intelligent control module. The pouring line module is an automated conveyor line with a demolding station at the front end and a track module at the rear end. The pouring line module is sequentially equipped with a mold cleaning station, a release agent spraying station, a steel cage and embedded part installation station, and a concrete pouring and vibration station along its conveying direction. The demolding station is used to remove the cured track slab from the mold, and the empty mold after demolding enters the subsequent process cycle of the casting line module. The transport module is used to transfer molds between the rear end of the casting line module, each curing kiln module and the demolding station. The track module provides a travel path for the transport module, and the track module connects the end of the casting line module, the inlet and outlet of each curing kiln module, and the demolding station; Each of the curing kiln modules is a closed curing unit that can be independently opened and closed and whose curing parameters can be independently adjusted; The intelligent control module is communicatively connected to the pouring line module, the handling module, the track module, and each curing kiln module, and is used to coordinate the production process, control the handling schedule, and monitor the curing parameters.
2. The independent kiln production line for subway track slabs as described in claim 1, characterized in that, The gating line module is arranged in a straight line or a ring, and uses a hydraulic or electric propulsion system to realize the step-by-step transmission of the mold.
3. The independent kiln production line for subway track slabs as described in claim 1, characterized in that, The transport module includes at least two independently operating mother and daughter vehicles, wherein the first vehicle is used to transport the mold after pouring and vibration from the pouring line module to the idle curing kiln module, and the second vehicle is used to transport the mold after curing from the curing kiln module back to the demolding station.
4. The independent kiln production line for subway track slabs as described in claim 3, characterized in that, The mother and daughter vehicles have lifting and lateral movement functions and can travel on the track module to automatically grab, transfer and place molds.
5. The independent kiln production line for subway track slabs as described in claim 1, characterized in that, Each curing kiln module is equipped with an independent kiln door, steam pipeline, temperature and humidity sensor and controller, which can realize independent start-up and shutdown and curing program control.
6. The independent kiln production line for subway track slabs as described in claim 1, characterized in that, The intelligent control module includes a central control unit, a human-machine interface, and a data server. The intelligent control module communicates with the casting line module, the handling module, the track module, and each curing kiln module through an industrial bus or wireless network to achieve automated control and data traceability of the entire production process.
7. A method for producing subway track slabs, using the production line described in any one of claims 1-6, characterized in that, Includes the following steps: After demolding, the empty mold automatically flows on the gating line module, passing through the mold cleaning station and the mold release agent spraying station in sequence for cleaning and mold release agent spraying operations; At the rebar cage and embedded parts installation station, install and fix the rebar cage, fastener sleeve, and lifting sleeve inside the mold; At the concrete pouring and vibration station, the concrete is layered and vibrated. After vibration, the mold is allowed to rest for a predetermined time, and then the first mother-daughter cart in the transport module transports it from the end of the casting line module to an empty curing kiln module. Close the kiln door of the curing kiln module and carry out independent steam curing according to the preset curing system. During the curing period, the mold remains stationary inside the kiln. After curing is completed, the second mother-daughter trolley in the transport module will transport the mold from the curing kiln module back to the demolding station for demolding of the track plate. The track slabs undergo subsequent curing after demolding.