Composite sleeper production device based on pultrusion process and production process thereof

Abstract

The invention discloses a composite sleeper production device based on a pultrusion process and a production process thereof, and relates to the technical field of production devices. A second unwinding roller; the bundling device is arranged on one side of the second unwinding roller; the resin processing device is mounted on the bundling device; and the rotary feeding device is mounted at the bottom of the resin processing device, and the rotary feeding device is used for feeding the resin in the resin processing device into the bundling device. The arrangement mode that the resin processing device and the rotary feeding device are matched is utilized, the reverse rotation speed of a servo motor is adjusted, the conveying speed of a feeding auger can be further finely adjusted, dynamic matching of the resin discharging amount and the pultrusion rhythm is achieved, manual material pushing by operators is not needed, discharging amount fluctuation caused by manual intervention is avoided, and the production efficiency is improved. The feeding stability is guaranteed, and the labor intensity of operators is relieved.

Description

Technical Field

[0001] This invention relates to the field of production equipment technology, and in particular to a composite sleeper production device and its production process based on pultrusion technology. Background Technology

[0002] In the field of rail transit infrastructure construction, composite sleepers, with their significant advantages such as lightweight, corrosion resistance, and long service life, are gradually replacing traditional concrete sleepers and becoming the core direction for sleeper material upgrades. Pultrusion, as a key technology for the large-scale production of composite sleepers, requires a process that strictly follows the sequence of fiber unwinding → resin impregnation → mold forming → traction cutting. The stability and efficiency of resin feeding into the impregnation frame directly determine the adequacy of fiber impregnation, thus affecting the mechanical properties and production rhythm of the composite sleeper. This is a core link restricting the production quality and efficiency of composite sleepers.

[0003] Currently, in composite sleeper production equipment based on pultrusion technology, the resin is typically fed into the resin impregnation mold by gravity. After processing, the resin flows directly into the impregnation frame through the outlet at the bottom of the feed tank, relying on its own weight. While this traditional feeding method is simple in structure and low in cost, it presents significant challenges in practical applications of composite sleeper production, contradicting the characteristics of high-viscosity resins and the demands for high-efficiency production. It has gradually revealed numerous unavoidable defects, particularly in resin feeding efficiency, stability, and compatibility, becoming a major bottleneck hindering the improvement of quality and efficiency in composite sleeper production.

[0004] To address the shortcomings of gravity-fed feeding, some production units have attempted to optimize the process by increasing the diameter of the feeding channel or by manually assisting with feeding. However, these improvements have significant limitations: while increasing the channel diameter can improve the feeding speed to some extent, it cannot solve the problem of stagnation in high-viscosity resins. Furthermore, an excessively large channel can lead to uncontrolled resin feeding, easily causing uneven resin distribution within the impregnation rack. Manual feeding requires frequent intervention from operators, which not only increases labor costs but also makes it difficult to ensure the stability of the feeding force and frequency, resulting in large fluctuations in the feeding volume. Summary of the Invention

[0005] The purpose of this invention is to provide a composite sleeper production apparatus and production process based on pultrusion technology to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a composite railway sleeper production apparatus based on pultrusion process, comprising:

[0007] A first unwinding roller is mounted on a first mounting frame and is used to unwind a bundle of glass fibers.

[0008] The second unwinding roller is mounted on the second mounting frame and is used to unwind the glass fiber mat.

[0009] A bundling device is located on one side of the second unwinding roll;

[0010] A resin processing apparatus, which is mounted on a bundling device;

[0011] A rotary feeder is installed at the bottom of the resin processing device and is used to feed resin from inside the resin processing device into the bundler.

[0012] Preferably, the clustering device includes:

[0013] The workbench, the first mounting bracket, the second mounting bracket and the workbench are arranged in sequence;

[0014] A hub, which is mounted on one side of the workbench;

[0015] A resin impregnation mold is mounted on a worktable, and a rotary feeding device is connected between the resin impregnation mold and the resin processing device.

[0016] Preferably, the resin processing apparatus includes:

[0017] A processing tank, which is mounted on a workbench;

[0018] A sealing cap, which is installed on the top of the processing tank;

[0019] A servo motor, which is mounted on top of the sealing cover;

[0020] A spindle, one end of which is connected to the output end of a servo motor;

[0021] A stirring blade is fixedly installed on the outside of the main shaft.

[0022] Preferably, the rotary feeder includes:

[0023] A feed tank, which is fixedly connected between the processing tank and the resin impregnation mold;

[0024] A feeding auger, which is rotatably disposed inside the feed tank;

[0025] A connecting column is connected to the other end of the main shaft, and the feeding auger is rotatably connected to the connecting column through a bearing.

[0026] Preferably, the rotary feeding device further includes:

[0027] An elastic compression mechanism is movably disposed inside the connecting column;

[0028] A one-way transmission mechanism is connected to the end of an elastic compression mechanism, and the elastic compression mechanism is used to provide elastic support for the one-way transmission mechanism.

[0029] A pressure regulating mechanism is installed on the outside of the connecting column and is used to adjust the position of the elastic extrusion mechanism.

[0030] Preferably, the elastic compression mechanism includes:

[0031] An elastic component is disposed inside the connecting column and is connected to a one-way transmission mechanism;

[0032] An extrusion assembly is inserted and mounted on an elastic assembly.

[0033] Preferably, the elastic component includes:

[0034] An insert rod, one end of which is connected to a one-way transmission mechanism, and the other end of which is slidably inserted into a connecting column;

[0035] A spring, which is movably sleeved on the outside of the insert rod.

[0036] Preferably, the extrusion assembly includes:

[0037] A compression ring, wherein the compression ring is slidably inserted into and connected to the insertion rod;

[0038] The slide rods are fixedly connected to both sides of the extrusion ring, and the slide rods are slidably inserted into the connecting column.

[0039] Preferably, the unidirectional transmission mechanism includes:

[0040] The first one-way toothed ring is fixedly connected to the feeding auger.

[0041] The second one-way toothed ring is fixedly connected to the insert rod;

[0042] A slider is fixedly connected to a second one-way toothed ring. A groove is provided inside the connecting column, and the slider slides in conjunction with the inner cavity of the groove.

[0043] The pressure regulating mechanism includes:

[0044] Nut seat, the nut seat being threaded onto the outside of the connecting column;

[0045] A rotating ring, which is rotatably mounted on a nut seat;

[0046] A support rod is fixedly installed between the rotating ring and the sliding rod.

[0047] The composite sleeper manufacturing process based on pultrusion includes the following steps:

[0048] S1, the glass fiber mat on the second unwinding roller and the glass fiber bundle on the first unwinding roller are inserted into the resin impregnation mold in a preset mat-bundle-mat sequence, and the glass fiber mat and glass fiber bundle are impregnated through the resin tank. After the resin is cured, a continuous profile of the composite sleeper is formed.

[0049] S2, when the servo motor rotates forward, the rotation of the stirring blades facilitates the stirring of the resin. At this time, the feeding auger is in a non-working state. When it is necessary to accelerate the addition of resin, the servo motor reverses, and the elastic extrusion mechanism provides elastic support to the one-way transmission mechanism, so that the vertical surfaces of the tooth grooves on the first one-way toothed ring and the second one-way toothed ring come into contact and press against each other. This allows the rotation of the second one-way toothed ring to synchronously drive the rotation of the second one-way toothed ring, which in turn drives the rotation of the feeding auger. Through the rotation of the feeding auger, the thick resin is fed into the interior of the resin impregnation mold.

[0050] The technical effects and advantages of this invention are as follows:

[0051] This invention utilizes a combination of a resin processing device and a rotary feeding device. When the servo motor rotates forward, the rotation of the stirring blades facilitates resin mixing and processing, and the feeding auger is in a non-working state. When faster resin addition is needed, the servo motor reverses, and the elastic extrusion mechanism provides elastic support to the unidirectional transmission mechanism. This causes the vertical surfaces of the tooth grooves on the first and second unidirectional toothed rings to press against each other, allowing the rotation of the second unidirectional toothed ring to synchronously drive its rotation, which in turn drives the feeding auger. The rotation of the feeding auger facilitates the delivery of viscous resin into the resin impregnation mold, accelerating the resin addition rate. The active rotation of the feeding auger generates a continuous thrust on the viscous resin, effectively overcoming the resin's viscous resistance and delivering the resin quickly and continuously into the resin impregnation mold. Compared to traditional gravity-fed feeding, this design significantly improves the feeding efficiency of high-viscosity resin. The flexible control of the feeding speed is achieved through the forward and reverse switching of the servo motor and the coordination of the rotary feeding device. During the resin processing stage, the servo motor is controlled to rotate forward. At this time, the feeding auger is not working, and only the stirring blades stir the resin to ensure uniform mixing. When the pultrusion speed increases and the amount of resin added needs to be increased, the servo motor is switched to reverse to start the feeding auger. By adjusting the reverse rotation speed of the servo motor, the conveying speed of the feeding auger can be further fine-tuned to achieve dynamic matching between the resin feeding amount and the pultrusion rhythm. There is no need for operators to manually push the material, avoiding fluctuations in the feeding amount caused by manual intervention, ensuring feeding stability, and reducing the labor intensity of operators. Attached Figure Description

[0052] Figure 1 This is a schematic diagram of the front structure of the present invention;

[0053] Figure 2 This is a schematic diagram of the internal structure of the resin processing device of the present invention;

[0054] Figure 3 For the present invention Figure 2 Enlarged structural diagram at point A in the middle;

[0055] Figure 4 This is a schematic diagram of the internal structure of the connecting column in this invention;

[0056] Figure 5 This is a schematic diagram of the unidirectional transmission mechanism of the present invention.

[0057] In the attached image:

[0058] 100. First unwinding roller; 200. Second unwinding roller; 300. Cable tray; 400. Resin impregnation mold; 500. Resin processing device; 501. Processing tank; 502. Sealing cover; 503. Servo motor; 504. Main shaft; 505. Stirring blade; 600. Rotary feeding device; 601. Feed tank; 602. Feeding auger; 603. Connecting column; 604. Elastic extrusion mechanism; 641. Inserting rod; 642. Spring; 643. Extrusion ring; 644. Slide rod; 605. One-way transmission mechanism; 651. First one-way toothed ring; 652. Second one-way toothed ring; 653. Slider; 606. Pressure adjustment mechanism; 661. Nut seat; 662. Rotating ring; 663. Support rod. Detailed Implementation

[0059] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0060] This invention provides, for example Figures 1-5The composite sleeper production apparatus based on pultrusion process shown includes: a first unwinding roller 100, mounted on a first mounting frame, used for unwinding glass fiber bundles; a second unwinding roller 200, mounted on a second mounting frame, used for unwinding glass fiber mats; a bundling device disposed on one side of the second unwinding roller 200; a resin processing device 500, mounted on the bundling device; and a rotary feeding device. A rotary feeder 600 is installed at the bottom of the resin processing device 500. The rotary feeder 600 is used to feed the resin inside the resin processing device 500 into the bundler. The rotation of the feeding auger 602 facilitates the feeding of viscous resin into the resin impregnation mold 400, thereby accelerating the resin addition speed. The active rotation of the feeding auger 602 generates a continuous thrust on the viscous resin, effectively overcoming the resin's viscous resistance and allowing the resin to be fed quickly and continuously into the resin impregnation mold 400. Compared to traditional gravity-fed feeding, this design significantly improves the feeding efficiency of high-viscosity resin. The flexible control of the feeding speed is achieved through the forward and reverse switching of the servo motor 503 in conjunction with the rotary feeder 600. During the resin processing stage, the servo motor 503 is controlled to rotate forward. At this time, the feeding auger 602 is not working, and only the stirring blade 505 stirs the resin to ensure uniform mixing. When the pultrusion speed increases and the amount of resin added needs to be increased, the servo motor 503 is switched to reverse to start the feeding auger 602. By adjusting the reverse rotation speed of the servo motor 503, the conveying speed of the feeding auger 602 can be further fine-tuned to achieve dynamic matching between the resin feeding amount and the pultrusion rhythm. There is no need for operators to manually push the material, which avoids fluctuations in the feeding amount caused by manual intervention, ensures feeding stability, and reduces the labor intensity of operators.

[0061] The bundling device includes: a worktable, a first mounting frame, a second mounting frame arranged sequentially with the worktable; a wire feeder 300 installed on one side of the worktable; a resin impregnation mold 400 installed on the worktable; and a rotary feeding device 600 connected between the resin impregnation mold 400 and the resin processing device 500. The wire feeder 300 facilitates the concentration of glass fiber mats and glass fiber bundles, while the resin impregnation mold 400 facilitates the shaping of the composite material.

[0062] The resin processing apparatus 500 includes: a processing tank 501 mounted on a workbench; a sealing cover 502 mounted on top of the processing tank 501; a servo motor 503 mounted on top of the sealing cover 502; a main shaft 504, one end of which is connected to the output end of the servo motor 503; and a stirring blade 505 fixedly mounted on the outside of the main shaft 504. A first flip cover is connected to the sealing cover 502 via a rotating shaft. The first flap is opened by rotating it, which facilitates the feeding of material into the inner cavity of the treatment tank 501. The bottom of the treatment tank 501 is rotatably connected to the second flap via a rotating shaft. Opening the second flap facilitates the operation of the rotary feeding device 600. A sealing ring is connected between the second flap and the treatment tank 501 to prevent resin leakage. The servo motor 503 drives the rotation of the main shaft 504, which in turn drives the rotation of the stirring blade 505, so that the stirring blade 505 can stir the resin inside the treatment tank 501.

[0063] Specifically, the rotary feeding device 600 includes: a feeding tank 601, which is fixedly connected between the processing tank 501 and the resin impregnation mold 400; a feeding auger 602, which is rotatably disposed inside the feeding tank 601; and a connecting column 603, which is connected to the other end of the main shaft 504, and the feeding auger 602 is rotatably connected to the connecting column 603 through a bearing. The rotary feeding device 600 further includes: an elastic extrusion mechanism 604, which is movably disposed inside the connecting column 603; a one-way transmission mechanism 605, which is connected to the end of the elastic extrusion mechanism 604 and provides elastic support for the one-way transmission mechanism 604; and a pressure regulating mechanism 606, which is installed outside the connecting column 603 and is used to adjust the position of the elastic extrusion mechanism 604. By rotating the feeding auger 602, the resin material in the processing tank 501 is easily fed into the resin impregnation mold 400.

[0064] Specifically, the elastic compression mechanism 604 includes: an elastic component disposed inside the connecting column 603 and connected to the one-way transmission mechanism 605; and a compression component inserted into the elastic component. The elastic component includes: an insertion rod 641, one end of which is connected to the one-way transmission mechanism 605, and the other end of which is slidably inserted into the connecting column 603; and a spring 642 movably sleeved outside the insertion rod 641. The extrusion assembly includes: an extrusion ring 643, which is slidably connected to the insertion rod 641; and a slide rod 644, which is fixedly connected to both sides of the extrusion ring 643 and is slidably connected to the connecting post 603. The compression deformation of the spring 642 facilitates the elastic support of the one-way transmission mechanism 605. The extrusion ring 643 facilitates the extrusion and limiting of the spring 642, further enhancing the elastic strength of the spring 642. The slidable connection between the slide rod 644 and the connecting post 603 makes the movement of the extrusion ring 643 more stable.

[0065] The one-way transmission mechanism 605 includes: a first one-way gear ring 651, which is fixedly connected to the feeding auger 602; a second one-way gear ring 652, which is fixedly connected to the insert rod 641; and a slider 653, which is fixedly connected to the second one-way gear ring 652. A groove is provided inside the connecting post 603, and the slider 653 slides within the groove. The pressure adjustment mechanism 606 includes: a nut seat 661, which is threaded onto the connecting post 603. Externally, a rotating ring 662 is rotatably mounted on a nut seat 661; a support rod 663 is fixedly installed between the rotating ring 662 and the slide rod 644. Through the rotatable connection between the nut seat 661 and the rotating ring 662, it is easy to neutralize the rotation of the nut seat 661. When the nut seat 661 rotates threadedly outside the connecting column 603, it can drive the support rod 663 to move up and down, further facilitating the height adjustment of the position of the compression ring 643 relative to the spring 642.

[0066] The composite sleeper manufacturing process based on pultrusion includes the following steps:

[0067] S1, the glass fiber mat on the second unwinding roller 200 and the glass fiber bundle on the first unwinding roller 100 are inserted into the resin impregnation mold 400 in a preset mat-bundle-mat sequence, and the glass fiber mat and glass fiber bundle are impregnated through the resin tank. After the resin is cured, a continuous profile of the composite sleeper is formed.

[0068] S2, when the servo motor 503 rotates forward, the rotation of the stirring blade 505 facilitates the stirring of the resin. At this time, the feeding auger 602 is in a non-working state. When it is necessary to accelerate the addition of resin, the servo motor 503 rotates in reverse, and the elastic extrusion mechanism 604 provides elastic support to the one-way transmission mechanism 605, so that the vertical surfaces of the tooth grooves on the first one-way toothed ring 651 and the second one-way toothed ring 652 are pressed together. This allows the rotation of the second one-way toothed ring 652 to be synchronously driven, which in turn drives the rotation of the feeding auger 602. Through the rotation of the feeding auger 602, the thick resin is fed into the interior of the resin impregnation mold 400.

[0069] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A composite railway sleeper production apparatus based on pultrusion process, characterized in that, include: A first unwinding roller (100) is mounted on a first mounting frame and is used to unwind glass fiber bundles. The second unwinding roller (200) is mounted on the second mounting frame and is used to unwind the glass fiber mat. A bundling device is disposed on one side of the second unwinding roll (200); A resin processing apparatus (500) is mounted on a bundled device; A rotary feeder (600) is installed at the bottom of the resin processing device (500) and is used to feed the resin inside the resin processing device (500) into the bundler.

2. The composite sleeper production apparatus based on pultrusion process according to claim 1, characterized in that, The clustering device includes: The workbench, the first mounting bracket, the second mounting bracket and the workbench are arranged in sequence; A hub (300) is mounted on one side of the workbench; A resin impregnation mold (400) is mounted on a workbench, and a rotary feeding device (600) is connected between the resin impregnation mold (400) and the resin processing device (500).

3. The composite sleeper production apparatus based on pultrusion process according to claim 1, characterized in that, The resin processing apparatus (500) includes: Processing tank (501), said processing tank (501) is mounted on the workbench; A sealing cap (502) is installed on top of the processing tank (501); A servo motor (503) is mounted on top of the sealing cover (502); A spindle (504), one end of which is connected to the output end of a servo motor (503); A stirring blade (505) is fixedly installed on the outside of the main shaft (504).

4. The composite sleeper production apparatus based on pultrusion process according to claim 1, characterized in that, The rotary feeder (600) includes: Feed tank (601), which is fixedly connected between processing tank (501) and resin impregnation mold (400); A feeding auger (602) is rotatably disposed inside the feed tank (601); A connecting column (603) is connected to the other end of the main shaft (504), and the feeding auger (602) is rotatably connected to the connecting column (603) through a bearing.

5. The composite sleeper production apparatus based on pultrusion process according to claim 4, characterized in that, The rotary feeder (600) further includes: An elastic compression mechanism (604) is movably disposed inside the connecting column (603); A one-way transmission mechanism (605) is connected to the end of an elastic compression mechanism (604), and the elastic compression mechanism (604) is used to provide elastic support for the one-way transmission mechanism (605). A pressure regulating mechanism (606) is installed on the outside of the connecting column (603) and is used to adjust the position of the elastic compression mechanism (604).

6. The composite sleeper production apparatus based on pultrusion process according to claim 5, characterized in that, The elastic compression mechanism (604) includes: An elastic component is disposed inside the connecting column (603) and is connected to a one-way transmission mechanism (605); An extrusion assembly is inserted and mounted on an elastic assembly.

7. The composite sleeper production apparatus based on pultrusion process according to claim 6, characterized in that, The elastic component includes: An insert rod (641) is provided, one end of which is connected to a one-way transmission mechanism (605), and the other end of which is slidably inserted into a connecting column (603). A spring (642) is movably sleeved on the outside of the insert rod (641).

8. The composite sleeper production apparatus based on pultrusion process according to claim 6, characterized in that, The extrusion assembly includes: A compression ring (643) is slidably inserted into and connected to a through rod (641); The slide rod (644) is fixedly connected to both sides of the compression ring (643), and the slide rod (644) is slidably inserted into the connecting column (603).

9. The composite sleeper production apparatus based on pultrusion process according to claim 5, characterized in that, The one-way transmission mechanism (605) includes: The first one-way toothed ring (651) is fixedly connected to the feeding auger (602); The second one-way toothed ring (652) is fixedly connected to the insert rod (641); The slider (653) is fixedly connected to the second one-way toothed ring (652). The connecting column (603) has a sliding groove inside, and the slider (653) slides in the inner cavity of the sliding groove. The pressure regulating mechanism (606) includes: Nut seat (661), which is threaded to the outside of the connecting column (603); A rotating ring (662) is rotatably mounted on a nut seat (661); A support rod (663) is fixedly installed between the rotating ring (662) and the slide rod (644).

10. A composite railway sleeper manufacturing process based on pultrusion, characterized in that, Includes the following steps: S1, the glass fiber mat on the second unwinding roller (200) and the glass fiber bundle on the first unwinding roller (100) are inserted into the resin impregnation mold (400) in a preset mat-bundle-mat sequence, and the glass fiber mat and glass fiber bundle are impregnated through the resin tank. After the resin is cured, a continuous profile of the composite sleeper is formed. S2, when the servo motor (503) rotates forward, the rotation of the stirring blade (505) facilitates the stirring of the resin. At this time, the feeding auger (602) is in a non-working state. When it is necessary to speed up the addition of resin, the servo motor (503) rotates backward, and the elastic extrusion mechanism (604) provides elastic support to the one-way transmission mechanism (605), so that the vertical surfaces of the tooth grooves on the first one-way toothed ring (651) and the second one-way toothed ring (652) fit together and press against each other, so that the rotation of the second one-way toothed ring (652) can synchronously drive the rotation of the second one-way toothed ring (652), which in turn drives the rotation of the feeding auger (602). Through the rotation of the feeding auger (602), the thick resin is fed into the interior of the resin impregnation mold (400).

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