A concrete molding device for manufacturing a sleeper and a method thereof

Abstract

The application discloses a concrete forming device for manufacturing sleepers and a method thereof, relates to the technical field of sleeper manufacturing, and comprises a working platform, a track, a guide rail wheel, a mold, a dragging device and a cleaning unit. The cleaning unit is provided with multiple groups, is uniformly arranged along the length direction of the mold, is fixed at the bottom of the dragging device and located above the mold, and the concrete blocks on the surface of the mold are removed by the movement of the dragging device. The cleaning unit is provided with two groups of flail beaters with opposite rotating directions. By controlling the rotating speed of the flail beaters, the flail beaters can be thrown out, and the inner wall of the mold is beaten, so that the concrete attached to the surface of the mold is separated from the mold. The technical effect of dynamically adapting the impact force to different adhesion states, avoiding damage to the mold, expanding the cleaning coverage, eliminating dead angles, uniformly and accurately spraying the release agent, improving the cleaning efficiency and the release effect, prolonging the service life of the mold and improving the forming quality of the sleeper can be achieved.

Description

Technical Field

[0001] This invention relates to the field of railway sleeper manufacturing technology, and in particular to a concrete molding apparatus and method for manufacturing railway sleepers. Background Technology

[0002] Concrete sleepers, also known as prestressed concrete sleepers, are the core load-bearing components of modern railway tracks. They are mainly made of high-strength concrete with an internal prestressed steel reinforcement skeleton, and are manufactured through vibration molding and steam curing. They are mainly used to fix the position of the rails, distribute the train load transmitted by the rails to the track bed, and maintain the stability of the track geometry. They are widely used in high-speed railways, heavy-haul railways, and conventional speed lines, and are a key basic component to ensure the safety and efficiency of train operation.

[0003] The typical process for forming railway sleepers is as follows: an iron mold is installed on a platform, a release agent is brushed inside the mold, and a pre-reserved column is added to the bottom for pre-reserved holes for sleeper installation. Then, steel wire is added to the mold, and finally, concrete is injected into the mold through a grouting machine. After the concrete in the mold is formed, the concrete sleeper is removed.

[0004] However, after concrete sleepers are formed and removed from the mold, a large amount of concrete often adheres to the inner wall of the mold. Although existing technologies remove the concrete by hammering, the hammering force is fixed and cannot be adjusted dynamically according to the different adhesion states of the concrete (such as differences in initial hardness and changes in wetness). For example, soft concrete in high humidity environments requires less force to avoid damaging the mold, while dry and hardened concrete requires greater impact force to effectively peel off. Existing technologies cannot meet this requirement, resulting in poor flexibility. Furthermore, the rigid hammering method is prone to damaging the mold. The complex curved surfaces of the mold inner wall (such as the rail groove and shoulder area) are prone to micro-cracks due to stress concentration, which will shorten the mold's lifespan in the long run. The area cleaned by hammering is limited, with many cleaning dead zones that traditional tools cannot reach. Residual concrete becomes a source of pollution in subsequent production, reducing the quality of subsequent sleeper forming.

[0005] In addition, the release agent is often applied in an intermittent manner, resulting in uneven spray volume and easy missed spraying. This can cause the release agent to accumulate at the bottom of the rail groove, forming droplets, which in turn aggravates the adhesion between the concrete and the mold, causing secondary adhesion, reducing the release effect, and even affecting the subsequent sleeper forming quality. This makes it difficult to meet the requirements of automated production for high efficiency, precision, and low consumption. Summary of the Invention

[0006] This application provides a concrete molding device and method for manufacturing railway sleepers, which solves the technical problems in the prior art, such as the fixed and unadjustable hammering force during mold inner wall cleaning, the inability to dynamically adjust the impact force according to different adhesion states, the tendency of rigid hammering to damage the mold, the limited cleaning area with dead corners, and the uneven spraying of release agent leading to missed spraying and accumulation, resulting in poor flexibility, short mold life, and poor demolding effect. The application achieves the technical effects of dynamically adapting the impact force to different adhesion states, avoiding mold damage, expanding the cleaning coverage, eliminating dead corners, uniform and precise spraying of release agent, improving cleaning efficiency and demolding effect, extending mold life, and improving the quality of railway sleeper molding.

[0007] This application provides a concrete molding apparatus for manufacturing railway sleepers, including a work platform, a track, guide wheels, a mold, a dragging device, and a cleaning unit;

[0008] The cleaning unit is provided in multiple sets, evenly arranged along the length of the mold, fixed at the bottom of the dragging device and located above the mold. By moving the dragging device, the cleaning unit removes the concrete blocks from the surface of the mold.

[0009] The cleaning unit has two sets of impact rollers rotating in opposite directions. By controlling the rotation speed of the impact rollers, the outer section of the impact roller is thrown out, thereby impacting the inner wall of the mold and causing the concrete adhering to the surface of the mold to detach from the mold.

[0010] Furthermore, the cleaning unit includes a connecting plate, a cover plate, a motor, a rotating shaft, a rotating column, and a sling roll;

[0011] Two connecting plates are provided, arranged front and back, and both are slidably connected to the bottom of the dragging device via electric sliders; the cover plate is fixed between the two connecting plates; the motor is a servo motor, fixed on the connecting plates, and used to drive the swinging roll to rotate; one end of the rotating shaft is coaxially fixedly connected to the motor output shaft, and the other end is rotatably connected inside the connecting plate; multiple rotating columns are provided, coaxially fixed on the rotating shaft; the swinging roll is a strip-shaped steel structure, multiple of which are provided, corresponding one-to-one with the rotating columns, and are respectively fixed on the outside of the corresponding rotating column.

[0012] Furthermore, the impact roller, rotating shaft, rotating column, and motor are all provided in two sets and arranged left and right; the impact rollers in the two sets are arranged alternately front and back, and are driven by the corresponding motors to rotate in opposite directions, so as to jointly impact the concrete attached to the inner wall of the mold and separate the concrete from the mold.

[0013] Furthermore, the swinging roll has two parts, namely an outer roll section and an inner roll section; the inner roll section is fixed on the rotating column; the outer roll section and the inner roll section are fixedly connected and rotated around the corresponding shaft by a corresponding motor, and the swinging and rewinding actions are completed during the rotation of the motor.

[0014] Furthermore, a compression bladder is fixed to the inner sidewall of the inner section of the swishing roll. The compression bladder has a strip-shaped bladder structure and is bonded and fixed to the inner sidewall of the swishing roll. The compression bladder is filled with a release agent.

[0015] Furthermore, the outer section of the sling roll is evenly provided with multiple injection ports in the middle. The middle of the outer section of the sling roll is a cavity structure. An injection pipe is fixed inside the cavity. The injection pipe is a flexible tube structure, and its tube wall is provided with through holes that communicate with and correspond one-to-one with the injection ports. The through holes are one-way membrane structures.

[0016] Furthermore, the outer section of the impact roll has a serrated structure, and multiple toothed blocks evenly fixed on the outer section of the impact roll have a conical structure, which are used to be thrown out of the outer section to perform multi-point hammering on the side wall and bottom of the mold.

[0017] Furthermore, the toothed block has an internal cavity filled with a non-Newtonian fluid. The cavity is sealed by a flexible membrane on the side of the toothed block away from the swirl, and the flexible membrane is made of flexible silicone.

[0018] When the motor drives the impact roller to rotate, the shape of the non-Newtonian fluid inside the tooth block changes with the rotation speed of the impact roller, thereby hammering the inner wall of the mold with different forces.

[0019] Furthermore, the clearing unit also includes a shovel and a spring;

[0020] The shovel plate has an arc-shaped structure and is fixed to the bottom of the towing device by a hinge seat; one end of the spring is welded to the bottom of the towing device and the other end is welded to the upper end of the shovel plate, which is used to remove the concrete attached to the mold.

[0021] Furthermore, the technical solution of the present invention also provides a concrete molding method for manufacturing railway sleepers, the specific steps of which are as follows:

[0022] Step 1: The dragging equipment moves along the track of the work platform via guide wheels, driving multiple sets of cleaning units to the top of the mold;

[0023] Step 2: Start the motor in the cleaning unit. The motor output shaft drives the rotating shaft to rotate, which in turn drives the corresponding coaxial fixed rotating column and the two sets of sling rolls to rotate synchronously and in opposite directions.

[0024] Step 3: The motor drives the outer section of the impact roll to rotate around the shaft and throw it out. At the same time, the compression bladder inside the inner section of the impact roll is squeezed, and the release agent is sprayed onto the mold surface through the spray pipe in the middle cavity of the outer section and from the spray nozzle.

[0025] Step 4: During the process of the outer section of the impact roll being thrown out, the toothed block is thrown out along with the outer section and hammers the side wall and bottom of the mold at multiple points. Furthermore, the shape and hardness of the non-Newtonian fluid inside the toothed block change with the rotation speed of the impact roll, allowing for flexible adjustment of the hammering force. The two sets of impact rolls rotate in opposite directions, working together to throw the attached concrete off the surface of the mold.

[0026] Step 5: After the outer roll section completes the swinging action, the motor drives it to rewind back to the inner roll section, restoring the initial state and preparing for the next cycle. The shovel plate maintains tension through the spring and moves with the dragging equipment to remove the concrete blocks that have not completely detached from the mold surface.

[0027] One or more technical solutions provided in this application have at least the following technical effects or advantages:

[0028] By using a swivel-driven roller to move toothed blocks, the non-Newtonian fluid inside the blocks changes shape with rotational speed, creating a "rate-correlated flexible impact" action, achieving dynamic force adjustment and solving the problem of fixed and unadjustable striking force. Through multi-point hammering by the serrated toothed blocks of the swivel-driven roller and elastic removal by the spring-loaded scraper, a "multi-point hammering + elastic contact" action is achieved, avoiding mold damage and eliminating dead zones. By squeezing the compression bladder as the swivel-driven roller is ejected, the release agent is simultaneously sprayed onto the mold through the spray pipe, creating a "synchronous extrusion spray" action, solving the problem of uneven release agent accumulation. Through the coordinated swivel of two sets of opposing swivel-driven rollers, a "bidirectional coordinated swivel" action is achieved, expanding the coverage area. This invention improves cleaning efficiency and effectively solves the technical problems of existing technologies, such as fixed and unadjustable hammering force during mold inner wall cleaning, inability to dynamically adjust impact force according to different adhesion states, rigid hammering easily damaging the mold, limited cleaning area with dead corners, uneven spraying of release agent leading to missed spraying and accumulation aggravating adhesion, resulting in poor flexibility, short mold life, and poor demolding effect. It achieves the technical effects of dynamically adapting to different adhesion states to adjust impact force, avoiding mold damage, expanding cleaning coverage, eliminating dead corners, uniform and precise spraying of release agent, improving cleaning efficiency and demolding effect, extending mold life, and improving sleeper forming quality. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of a concrete molding device for manufacturing railway sleepers according to the present invention.

[0030] Figure 2 This is a schematic diagram of the dragging device and the cleaning unit of a concrete forming apparatus for making railway sleepers according to the present invention.

[0031] Figure 3 This is a partial structural cross-sectional view of the dragging device and cleaning unit of a concrete forming apparatus for manufacturing railway sleepers according to the present invention.

[0032] Figure 4This is a schematic diagram of a single cleaning unit of a concrete forming apparatus for manufacturing railway sleepers according to the present invention.

[0033] Figure 5 This is a schematic diagram of the longitudinal structure of the impact coil and mold of a concrete forming device for manufacturing railway sleepers according to the present invention.

[0034] Figure 6 This is a schematic diagram of a single slammed roll of concrete from a concrete forming device for manufacturing railway sleepers according to the present invention.

[0035] Figure 7 This is a top view of a concrete forming device for manufacturing railway sleepers according to the present invention.

[0036] Figure 8 This invention relates to a concrete molding apparatus for manufacturing railway sleepers. Figure 7 Full sectional view along the AA direction.

[0037] Figure 9 This invention relates to a concrete molding apparatus for manufacturing railway sleepers. Figure 7 Full sectional view from the center BB direction.

[0038] In the diagram: 100, working platform; 101, track; 110, guide wheel; 120, mold; 130, dragging device; 200, cleaning unit; 210, connecting plate; 211, electric slider; 220, cover plate; 230, motor; 231, rotating shaft; 232, rotating column; 240, impact coil; 241, toothed block; 242, non-Newtonian fluid; 250, compression bladder; 251, release agent; 252, spray pipe; 253, spray nozzle; 260, shovel plate; 261, spring. Detailed Implementation

[0039] To facilitate understanding of the present invention, a more complete description of this application will be given below with reference to the accompanying drawings, which illustrate preferred embodiments of the invention. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to enable a more thorough and complete understanding of the disclosure of the present invention.

[0040] It should be noted that the terms "vertical," "horizontal," "up," "down," "left," "right," and similar expressions used in this article are for illustrative purposes only and do not represent the only possible implementation.

[0041] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains; the terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to limit the invention; the term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0042] Please see Figure 1 This is a schematic diagram of the overall structure of a concrete forming device for manufacturing railway sleepers according to the present invention. The concrete forming device of this application achieves dynamic force adjustment impact by incorporating a non-Newtonian fluid 242 within the toothed block 241, which changes shape with the rotation speed of the impact roll 240 (i.e., slow rotation with liquid buffer, fast rotation with solid-like increase in hammering force). Through multi-point hammering by the serrated toothed blocks 241 of the impact roll 240, and the elastic removal by the shovel plate 260 and spring 261, damage to the mold 120 and elimination of dead corners can be avoided. By squeezing the compression bladder 250 during ejection and simultaneously spraying the release agent 251 using the spray pipe 252 during ejection, uneven spray volume accumulation is resolved. The coordinated action of two sets of opposing impact rolls 240 expands coverage and improves efficiency. This achieves the technical effects of dynamically adapting to different adhesion states to adjust the impact force, avoiding mold damage, expanding cleaning coverage, eliminating dead corners, uniform and precise spraying of the release agent, improving cleaning efficiency and demolding effect, extending mold life, and improving the quality of railway sleeper forming.

[0043] Example 1: As Figures 1 to 3 As shown, this application discloses a concrete molding device for manufacturing railway sleepers, including a work platform 100, a track 101, guide wheels 110, a mold 120, a dragging device 130, and a cleaning unit 200.

[0044] Multiple sets of the cleaning unit 200 are evenly arranged along the length of the mold 120, fixed at the bottom of the dragging device 130 and located above the mold 120. By moving the dragging device 130, the cleaning unit 200 removes the concrete blocks from the surface of the mold 120.

[0045] The cleaning unit 200 has two sets of impact rollers 240 rotating in opposite directions. By controlling the rotation speed of the impact rollers 240, the outer section of the impact rollers 240 is thrown out, thereby impacting the inner wall of the mold 120, causing the concrete adhering to the surface of the mold 120 to detach from the mold 120.

[0046] like Figures 2 to 6 As shown, the cleaning unit 200 includes a connecting plate 210, a cover plate 220, a motor 230, a rotating shaft 231, a rotating column 232, and a sling roll 240;

[0047] Two connecting plates 210 are provided, arranged front and back, and both are slidably connected to the bottom of the dragging device 130 via electric sliders 211; the cover plate 220 is fixed between the two connecting plates 210; the motor 230 is a servo motor, fixed on the connecting plate 210, and used to drive the swinging roll 240 to rotate; one end of the rotating shaft 231 is coaxially fixedly connected to the output shaft of the motor 230, and the other end is rotatably connected inside the connecting plate 210; multiple rotating columns 232 are provided and coaxially fixed on the rotating shaft 231; the swinging roll 240 is a strip-shaped steel structure, multiple of which are provided, corresponding one-to-one with the rotating columns 232, and are respectively fixed on the outside of the corresponding rotating column 232.

[0048] like Figure 4 and Figure 5 As shown, the impact roller 240, the rotating shaft 231, the rotating column 232 and the motor 230 are all provided in two sets and arranged left and right; the impact rollers 240 in the two sets are arranged alternately front and back, and are driven by the corresponding motors 230 to rotate in opposite directions, and together they impact the concrete attached to the inner wall of the mold 120 to separate the concrete from the mold 120.

[0049] The sling roll 240 has two parts, namely an outer roll section and an inner roll section; the inner roll section is fixed on the rotating column 232; the outer roll section and the inner roll section are fixedly connected and are driven by the corresponding motor 230 to rotate around the corresponding rotating shaft 231, and the sling and roll-up actions are completed during the rotation of the motor 230.

[0050] This application, by setting up a cleaning unit 200 and controlling the rotation speed of two sets of impact rollers 240 to make the corresponding outer roller segments throw out at different speeds, performs multiple coordinated and reverse impact actions on the inner wall of the mold 120. That is, the two sets of impact rollers 240 rotate synchronously in opposite directions to jointly impact the inner wall of the mold 120, which can further cover and expand the cleaning range through reverse impact. It can also achieve continuous cleaning through the cycle of "throwing out and impacting - rewinding and resetting", and enhance the impact force of impact through the accumulation and release of potential energy, so as to achieve the detachment of concrete blocks. It can solve the problems of limited area and single force of traditional single-point knocking cleaning. Furthermore, the connecting plate 210 can also be moved by the electric slider 211 to adjust the impact range of the impact rollers 240 in real time, further reducing the cleaning dead corners.

[0051] Specifically, motor 230 drives two sets of impact rolls 240 to rotate in opposite directions around the corresponding shaft 231. Motor 230 first uses a slow speed to tighten the inner section of the impact roll 240, storing elastic potential energy. When the potential energy accumulates to the pressure threshold, motor 230 switches to a high speed, driving the two sets of impact rolls 240 to rotate rapidly in sync, causing the outer section to be thrown out and releasing potential energy to strike the inner wall and bottom of the mold 120, thereby breaking up the concrete attached to the mold 120 and facilitating subsequent cleaning and collection.

[0052] like Figures 4 to 9 As shown, a compression bladder 250 is fixed to the inner wall of the inner rolling section of the swishing roll 240. The compression bladder 250 is a strip-shaped bladder structure and is bonded and fixed to the inner rolling section of the swishing roll 240. The compression bladder 250 is filled with a release agent 251.

[0053] The outer section of the swishing roll 240 has multiple spray nozzles 253 evenly distributed in the middle. The middle section of the outer section of the swishing roll 240 has a cavity structure. Inside the cavity, a spray pipe 252 is fixed. The spray pipe 252 has a flexible tube structure, and its tube wall has through holes that communicate with and correspond one-to-one with the spray nozzles 253. The through holes have a one-way membrane structure.

[0054] This application addresses the issue of mold release agent 251 by installing a compression bladder 250 filled with a release agent 251 on the inner wall of the inner section of the sling roll 240 and a spray pipe 252 inside the outer section of the sling roll 240. During the ejection process of the outer section of the sling roll 240, the inner section is compressed, causing the compression bladder 250 to be squeezed and the release agent 251 to be "synchronously extruded." This achieves simultaneous release of the release agent 251 during the slinging process, ensuring that the release agent 251 accurately adheres to the surface of the mold 120 during the slinging action, avoiding intermittent spraying and missed areas, and thus solving the problem of mold release agent... The uneven adhesion caused by the disconnect between the spraying and cleaning actions of 251 further enhances the demolding coordination. At the same time, in conjunction with the compression bladder 250, the unidirectional membrane structure of the spray pipe 252 (the unidirectional membrane plays a flow control role) allows the release agent 251 to be "uniformly sprayed" from the spray nozzle 253 during extrusion, thereby covering the outer roll section impact area. This ensures that the distribution is precisely matched to the impact range, avoids accumulation at the bottom of the rail groove, and further solves the problems of uneven spraying of release agent 251 and increased adhesion due to accumulated droplets, thus improving demolding accuracy.

[0055] like Figures 4 to 9 As shown, the outer section of the impact roll 240 has a serrated structure, and the multiple toothed blocks 241 uniformly fixed on the outer section of the impact roll 240 have a conical structure, which are used to be thrown out of the outer section to perform multi-point hammering on the side wall and bottom of the mold 120.

[0056] The toothed block 241 has an internal cavity filled with a non-Newtonian fluid 242. The cavity is sealed by a flexible membrane on the side of the toothed block 241 away from the swiping roll 240. The flexible membrane is made of flexible silicone.

[0057] When the motor 230 drives the impact roller 240 to rotate, the shape of the non-Newtonian fluid 242 inside the tooth block 241 changes with the rotation speed of the impact roller 240, thereby hammering the inner wall of the mold 120 with different forces.

[0058] This application optimizes the structure of the sling roll 240 by employing an outer roll segment with a serrated structure containing toothed blocks 241. The toothed blocks 241 are filled with a non-Newtonian fluid 242, and the side of the toothed blocks 241 that contacts the inner wall of the mold 120 during ejection is designed as a flexible membrane. This allows the toothed blocks 241 to undergo different morphological changes during ejection at different speeds. Specifically, the shear-thickening properties of the non-Newtonian fluid 242 cause the contact stiffness to dynamically change with the rotational speed. Simultaneously, the inertia of the non-Newtonian fluid 242 causes the flexible membrane to undergo shape changes under its influence. (That is, the flexible membrane becomes sharper or blunter), so when it is thrown out and comes into contact with the inner wall of the mold 120, the hammering force on the concrete block attached to the inner wall of the mold 120 changes to different degrees, that is, the hammering state of the actual crushed concrete changes; and when the outer roll section is thrown out, the conical toothed block 241 uses a "multi-point hammering" action to achieve multi-point impact and act on the side wall and bottom of the mold 120. By using multi-point hammering to disperse stress, the peeling effect on the attached concrete block is enhanced (especially for dry hard concrete). This can solve the problem of single-point stress concentration and low peeling efficiency of traditional rigid hammering, and improve the adaptability to complex attachment states.

[0059] Specifically, when the motor 230 drives the outer section of the impact roller 240 to rotate and be thrown out around the shaft 231, the toothed block 241 rotates synchronously with the outer section. The morphology of the non-Newtonian fluid 242 inside it dynamically changes adaptively with the rotation speed of the impact roller 240 (i.e., at a slow speed, the non-Newtonian fluid 242 is in a liquid state, and the hammering force is relatively gentle; at a high speed, the non-Newtonian fluid 242 is in a near-solid state, and its corresponding hammering force will increase), realizing a "rate-correlated flexible impact" action, and adjusting the hardness of the hammering according to the rotation speed. The low-speed rotation impact mode is dynamically suitable for high-moisture soft concrete (slow speed, low force to prevent damage), while the high-speed rotation impact mode is dynamically suitable for dry hardened concrete (high speed, high force, strong peeling), further improving the flexibility of this device, realizing flexible adjustment of the hammering force, adapting to different adhesion states, and achieving "rigid and flexible" precise cleaning.

[0060] like Figure 3 As shown, the clearing unit 200 also includes a shovel plate 260 and a spring 261;

[0061] The shovel plate 260 has an arc-shaped structure and is fixed to the bottom of the towing device 130 by a hinge seat; one end of the spring 261 is welded and fixed to the bottom of the towing device 130, and the other end is welded and fixed to the upper end of the shovel plate 260. It is used to follow the movement of the towing device 130 and remove the concrete attached to the mold 120 after the impact roller 240 hammers the concrete.

[0062] The towing device 130 moves on the working platform 100 via the rail 101 and guide wheel 110 at both ends, and is used to thread the wire rope into the mold 120 to meet the requirements of sleeper forming; the guide wheel 110 and the rail 101 are used to support and guide the movement of the towing device 130, which is existing technology and will not be described in detail here.

[0063] like Figures 1 to 9 As shown, a method of using a concrete molding apparatus for manufacturing railway sleepers (i.e., a concrete molding method for manufacturing railway sleepers) according to an embodiment of this application is as follows:

[0064] Step 1: The dragging device 130 moves on the track 101 of the work platform 100 via the guide wheel 110, driving multiple sets of cleaning units 200 to reach above the mold 120;

[0065] Step 2: Start the motor 230 in the clearing unit 200. The output shaft of the motor 230 drives the rotating shaft 231 to rotate, which in turn drives the corresponding coaxially fixed rotating column 232 to rotate synchronously and in opposite directions with the two sets of sling rolls 240.

[0066] Step 3: The motor 230 drives the outer section of the impact roll 240 to rotate around the shaft 231 and throw it out. At the same time, the compression bladder 250 inside the inner section of the impact roll 240 is squeezed, and the release agent 251 is sprayed onto the surface of the mold 120 through the spray pipe 252 in the middle cavity of the outer section and from the spray port 253.

[0067] Step 4: During the process of the outer section of the impact roll 240 being thrown out, the toothed block 241 is thrown out along with the outer section and hammers the side wall and bottom of the mold 120 at multiple points. Furthermore, the shape and hardness of the non-Newtonian fluid 242 inside the toothed block 241 change with the rotation speed of the impact roll 240, flexibly adjusting the hammering force. The two sets of impact rolls 240 rotate in opposite directions, together throwing the attached concrete off the surface of the mold 120.

[0068] Step 5: After the outer roll section completes the swinging action, the motor 230 drives it to rewind back to the inner roll section, restore the initial state, and prepare for the next cycle. The shovel plate 260 maintains tension through the spring 261 and moves with the dragging device 130 to remove the concrete blocks that have not completely detached from the surface of the mold 120, thus completing the cleaning of the mold 120.

[0069] Step Six: After the cleaning is completed, the dragging device 130 has moved along the track 101 and threaded the wire rope into the mold 120 to meet the requirements for sleeper forming. Then, the dragging device 130 stops moving, the motor 230 is turned off, and the device enters the standby state. At this time, concrete is injected into the mold 120 by the grouting machine. After the concrete in the mold 120 is formed, the concrete sleeper is taken out.

[0070] The technical solutions described in the embodiments of this application have at least the following technical effects or advantages:

[0071] Through multiple sets of coordinated impact-type cleaning units 200, the problems of "fixed force, mold damage, dead corner residue, and uneven demolding" in traditional cleaning can be comprehensively solved, meeting the needs of high efficiency, precision, and low consumption in automated production. It achieves the technical effects of dynamically adapting to different adhesion states to adjust the impact force, avoiding mold damage, expanding cleaning coverage, eliminating dead corners, uniform and precise spraying of release agent, improving cleaning efficiency and demolding effect, extending mold life, and improving sleeper forming quality.

[0072] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. For those skilled in the art, the present invention can have various modifications and variations. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A concrete molding apparatus for manufacturing railway sleepers, comprising a work platform (100), a track (101), guide wheels (110), a mold (120), a dragging device (130), and a cleaning unit (200), characterized in that: The towing device (130) moves on the work platform (100) at both ends via rails (101) and guide wheels (110) to thread the wire rope into the mold (120) to meet the requirements for sleeper forming; the guide wheels (110) and rails (101) are used to support and guide the movement of the towing device (130); Multiple sets of the cleaning unit (200) are arranged evenly along the length of the mold (120), fixed at the bottom of the dragging device (130) and located above the mold (120). By moving the dragging device (130), the cleaning unit (200) removes the concrete blocks from the surface of the mold (120). The clearing unit (200) has two sets of impact rolls (240) rotating in opposite directions. By controlling the rotation speed of the impact rolls (240), the outer roll section of the impact rolls (240) is thrown out, thereby impacting the inner wall of the mold (120) so that the concrete attached to the surface of the mold (120) is removed from the mold (120). The cleaning unit (200) includes a connecting plate (210), a cover plate (220), a motor (230), a rotating shaft (231), a rotating column (232), and a sling roll (240). Two connecting plates (210) are provided, arranged front and back, and are slidably connected to the bottom of the dragging device (130) by electric sliders (211); the cover plate (220) is fixed between the two connecting plates (210); the motor (230) is a servo motor, fixed on the connecting plate (210), and is used to drive the swing roll (240) to rotate; one end of the rotating shaft (231) is coaxially fixedly connected to the output shaft of the motor (230), and the other end is rotatably connected to the inside of the connecting plate (210); multiple rotating columns (232) are provided, and are coaxially fixed on the rotating shaft (231); the swing roll (240) is a strip-shaped steel structure, and multiple of them are provided, corresponding one-to-one with the rotating columns (232), and are respectively fixed on the outside of the corresponding rotating columns (232); The impact roller (240), rotating shaft (231), rotating column (232) and motor (230) are all provided in two sets and arranged left and right; the impact rollers (240) in the two sets are arranged alternately front and back, and are driven by the corresponding motor (230) to rotate in opposite directions, and together impact the concrete attached to the inner wall of the mold (120) to separate the concrete from the mold (120). The swing roll (240) has two parts, namely an outer roll section and an inner roll section; the inner roll section is fixed on the rotating column (232); the outer roll section and the inner roll section are fixedly connected and driven by the corresponding motor (230) to rotate around the corresponding rotating shaft (231), and the swinging and rewinding actions are completed during the rotation of the motor (230).

2. The concrete molding device for manufacturing railway sleepers as described in claim 1, characterized in that, A compression bladder (250) is fixed to the inner wall of the inner roll section of the slap roll (240). The compression bladder (250) is a strip-shaped bladder structure and is bonded and fixed to the inner roll section of the slap roll (240). The compression bladder (250) is filled with a release agent (251).

3. A concrete molding device for manufacturing railway sleepers as described in claim 2, characterized in that, The outer section of the sling roll (240) is evenly provided with multiple spray nozzles (253). The outer section of the sling roll (240) is a cavity structure. Inside the cavity, a spray pipe (252) is fixed. The spray pipe (252) is a flexible tube structure, and its tube wall is provided with through holes that are connected to and correspond one-to-one with the spray nozzles (253). The through holes are one-way membrane structures.

4. A concrete molding device for manufacturing railway sleepers as described in claim 3, characterized in that, The outer section of the sling roll (240) has a serrated structure, and multiple toothed blocks (241) uniformly fixed on the outer section of the sling roll (240) have a conical structure, which are used to sling out from the outer section and perform multi-point hammering on the side wall and bottom of the mold (120).

5. A concrete molding device for manufacturing railway sleepers as described in claim 4, characterized in that, The tooth block (241) has an internal cavity, which is filled with a non-Newtonian fluid (242). The tooth block (241) is separated from the swirl roll (240) by a flexible membrane, which is made of flexible silicone. When the motor (230) drives the slamming roller (240) to rotate, the shape of the non-Newtonian fluid (242) in the tooth block (241) changes with the rotation speed of the slamming roller (240), thereby pounding the inner wall of the mold (120) with different forces.

6. A concrete molding device for manufacturing railway sleepers as described in claim 1, characterized in that, The clearing unit (200) also includes a shovel (260) and a spring (261); The shovel plate (260) has an arc-shaped structure and is fixed to the bottom of the dragging device (130) by a hinge seat; one end of the spring (261) is welded to the bottom of the dragging device (130) and the other end is welded to the upper end of the shovel plate (260) to remove the concrete attached to the mold (120).

7. A concrete molding method for manufacturing railway sleepers, employing a concrete molding apparatus for manufacturing railway sleepers as described in any one of claims 1-6, characterized in that, Includes the following: Step 1: The dragging device (130) moves on the track (101) of the work platform (100) via the guide wheel (110), driving multiple sets of cleaning units (200) to reach above the mold (120); Step 2: Start the motor (230) in the clearing unit (200). The output shaft of the motor (230) drives the rotating shaft (231) to rotate, thereby driving the corresponding coaxial fixed rotating column (232) to rotate synchronously and in opposite directions with the two sets of sling rolls (240); Step 3: The motor (230) drives the outer section of the sling roll (240) to rotate around the shaft (231) and throw it out. At the same time, the compression bladder (250) inside the inner section of the sling roll (240) is squeezed, and the release agent (251) is sprayed onto the surface of the mold (120) through the spray pipe (252) in the middle cavity of the outer section and from the spray port (253). Step 4: During the process of the outer section of the impact roll (240) being thrown out, the toothed block (241) is thrown out along with the outer section and hammers the side wall and bottom of the mold (120) at multiple points. In addition, the shape and hardness of the non-Newtonian fluid (242) inside the toothed block (241) change with the rotation speed of the impact roll (240), and the hammering force is flexibly adjusted. The two sets of impact rolls (240) rotate in opposite directions and together throw the attached concrete off the surface of the mold (120). Step 5: After the outer roll section completes the swinging action, the motor (230) drives it to rewind back to the inner roll section, restore the initial state, and prepare for the next cycle. The shovel plate (260) maintains tension through the spring (261) and moves with the dragging device (130) to remove the concrete blocks that have not completely detached from the surface of the mold (120).

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