Energy-saving railway concrete sleeper steam curing equipment

Abstract

The application discloses an energy-saving railway concrete sleeper steam curing equipment, which comprises a device frame, universal wheels and a detection mechanism, wherein the detection mechanism is arranged on a top plate and electrically connected with a soft control unit; the detection mechanism comprises a mounting box, a temperature sensor, a humidity sensor, a circuit board and a sealing cover; a liquid inlet valve, an electromagnetic valve, a Y-shaped metal connecting pipe, a steam outlet valve and a display panel are arranged on the top plate; and the device frame is provided with a heat dissipation plate, a control panel, a side plate and connecting wires. The soft control unit is integrated with data acquisition, data preprocessing, self-adaptive curing control, instruction output, man-machine interaction, fault warning and interlocking control modules. The equipment collects environmental temperature and humidity, liquid inflow, medium parameters, equipment and valve state data, matches a curing stage after processing, generates a control instruction to adjust the opening degrees of the electromagnetic valve and the steam outlet valve, forms a closed loop control, outputs warning information and executes interlocking shutdown when parameters are abnormal or elements are faulty.

Description

Technical Field

[0001] This invention relates to the field of steam curing equipment technology, and in particular to an energy-saving steam curing equipment for railway concrete sleepers. Background Technology

[0002] Railway concrete sleepers are key load-bearing components of railway tracks. Their strength, density, and durability directly affect traffic safety and the service life of the track. Steam curing is the core process in sleeper production and on-site maintenance. It can accelerate cement hydration, shorten the curing cycle, inhibit drying shrinkage and temperature difference cracks, and ensure that the mechanical properties of the sleepers meet the requirements of railway use through a constant temperature and humidity environment.

[0003] Existing maintenance equipment mostly adopts a fixed frame structure and is used in conjunction with an external steam generator for maintenance. This results in insufficient operational flexibility and makes it difficult to adapt to the needs of multi-station operation and multi-point on-site maintenance. The maintenance process relies on manual judgment of environmental parameters based on experience and manual control of the steam and liquid inlet pipelines, resulting in low control accuracy and poor consistency.

[0004] Meanwhile, existing equipment is generally equipped with only simple temperature measuring elements, lacking integrated temperature and humidity detection structures and sealing protection designs, resulting in insufficient stability of monitoring data and inability to achieve precise control of maintenance parameters; excessively high temperature and humidity can easily cause internal defects in concrete, while excessively low temperature and humidity can lead to insufficient hydration, prolonged maintenance cycle, and substandard sleeper strength.

[0005] In addition, most existing equipment uses a simple on / off control system without adaptive adjustment or closed-loop control logic. Excessive steam supply leads to energy waste, and the lack of fault warning and safety interlock mechanisms makes it difficult to guarantee the safety of equipment operation and the stability of maintenance quality. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of existing technologies and propose an energy-saving steam curing device for railway concrete sleepers.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: an energy-saving railway concrete sleeper steam curing equipment, comprising a device frame and casters, wherein the device frame is composed of columns, a top plate and a bottom plate fixedly connected, and the casters are rectangularly distributed and installed at the bottom of the bottom plate, characterized in that: a detection mechanism for real-time detection of temperature and humidity parameters of the environment in which the equipment is placed is fixedly installed on the top plate; The detection mechanism is electrically connected to a soft-connection control unit, which is electrically connected to a solenoid valve, a steam ejection valve, a flow meter, a detector, a control board, and a display panel. The soft-connection control unit is used to receive collected parameter data, perform data processing, generate maintenance control strategies, and output control commands to the corresponding actuators.

[0008] Preferably, the detection mechanism includes a mounting box, a temperature sensor, a humidity sensor, a circuit board, and a sealing cover; the mounting box is fixedly connected to the upper surface of the top plate, and the bottom of the mounting box has a vertically downward-facing wire hole for threading wires; both the temperature sensor and the humidity sensor are installed through the mounting box body, and the temperature sensor and the humidity sensor are located on the same side of the mounting box with their detection ends extending to the outside of the mounting box; the circuit board is detachably mounted inside the mounting box by bolts and is electrically connected to the temperature sensor and the humidity sensor; the sealing cover is detachably closed to the top of the mounting box by a fixing pin.

[0009] Preferably, the top plate is also equipped with an inlet valve, a solenoid valve, and a Y-shaped metal connecting pipe; the inlet valve has a manual adjustment structure for controlling the inlet flow rate; the solenoid valve is fixedly installed at one end of the inlet valve near the top plate; the Y-shaped metal connecting pipe is fixedly installed on one side above the top plate, with one end of the Y-shaped metal connecting pipe connected to the inlet pipeline and the other two ends respectively fixedly installed with a flow meter and a detector, the flow meter being used to monitor the inlet flow rate and the detector being used to detect the inlet water quality or steam purity.

[0010] Preferably, a steam ejection valve is fixedly installed on the other side of the Y-shaped metal connecting pipe above the top plate, and the steam ejection valve is connected to the steam generating mechanism; a display panel is fixedly installed at one end of the top plate, and the display panel is electrically connected to the circuit board, flow meter, and detector for real-time display of maintenance-related data.

[0011] Preferably, a heat sink is fixedly installed between the columns at both ends of the device frame, and the heat sink is made of metal; a control board is fixedly installed on the outer surface of one of the heat sinks, and the control board integrates a control switch and a status indicator light.

[0012] Preferably, side plates are fixedly installed between the columns on both sides of the device frame, and the side plates are used to close the side of the device frame; a connecting wire is fixedly installed on one side of the side plate, and one end of the connecting wire is electrically connected to the control board and the circuit board.

[0013] Preferably, the soft-connect control unit includes a data acquisition module, a data preprocessing module, an adaptive maintenance control module, an instruction output module, and a human-machine interaction module; the input terminals of the data acquisition module are electrically connected to the detection mechanism, flow meter, detector, and control board, respectively; the output terminal of the data acquisition module is electrically connected to the input terminal of the data preprocessing module; the output terminal of the data preprocessing module is electrically connected to the input terminal of the adaptive maintenance control module; the output terminal of the adaptive maintenance control module is electrically connected to the input terminals of the instruction output module and the human-machine interaction module, respectively; and the output terminal of the instruction output module is electrically connected to the solenoid valve, steam injection valve, control board, and display panel, respectively.

[0014] Preferably, the data acquisition module is used to acquire multiple parameter data at a preset cycle. The parameter data includes ambient temperature and humidity data output by the detection mechanism, liquid flow rate data output by the flow meter, medium parameter data output by the detector, equipment operating status data output by the control board, and valve status feedback data output by the solenoid valve and steam ejection valve. The data preprocessing module is used to perform filtering, outlier removal, format conversion and normalization on the acquired parameter data, and output the processed parameter data to the adaptive maintenance control module.

[0015] Preferably, the adaptive maintenance control module receives preprocessed parameter data, matches it with preset sleeper maintenance stage division rules, and determines the current target stage of maintenance; retrieves the target parameter range and control weight parameters corresponding to the target stage, and calculates the steam supply adjustment parameters and liquid inlet adjustment parameters for the current stage by combining the real-time collected temperature and humidity change rate, medium parameters, and maintenance duration; generates corresponding opening control commands based on the calculated adjustment parameters, and sends them to the solenoid valve and steam ejection valve through the command output module to adjust the opening of the corresponding valves; and dynamically updates the adjustment parameters and control commands based on the deviation between the real-time collected parameter data and the target parameter range, forming a full-cycle closed-loop control.

[0016] Preferably, the soft-control unit further includes a fault warning and interlock control module. The input terminal of the fault warning and interlock control module is electrically connected to the data acquisition module, and the output terminal is electrically connected to the human-machine interaction module and the instruction output module, respectively. The fault warning and interlock control module is used to compare the acquired parameter data with a preset safety threshold range. When the parameter data exceeds the safety threshold range, or when abnormal status feedback data of the actuator is received, a warning command is generated and sent to the human-machine interaction module, and the warning information is output through the display panel and control board. At the same time, an interlock control command is generated to close the solenoid valve and the steam injection valve through the instruction output module, cutting off the medium supply.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. This solution, through the establishment of an integrated sealed detection mechanism, combined with temperature and humidity sensors, circuit boards, and a sealing cover, can simultaneously collect temperature and humidity parameters of the curing environment. This solves the problems of existing equipment that only has a single temperature measuring element, low monitoring accuracy, and poor data stability. It can obtain accurate environmental parameters in real time, providing reliable data support for curing control, avoiding improper control of curing parameters due to temperature and humidity acquisition deviations, reducing internal defects in concrete, insufficient hydration, and substandard sleeper strength, and improving the accuracy and stability of curing data collection.

[0018] 2. This solution uses a soft-control unit to automate the entire process of data acquisition, preprocessing, adaptive control, and command output, replacing manual valve operation based on experience. This solves the problems of existing equipment relying on manual operation and inefficient control. It can match corresponding control strategies according to the maintenance stage, dynamically adjust the opening of solenoid valves and steam injection valves to form closed-loop control, shorten the maintenance cycle, ensure the consistency of maintenance quality of sleepers in the same batch, reduce excessive steam supply, reduce energy consumption, and achieve energy-saving operation.

[0019] 3. This solution, by setting up a fault early warning and interlock control module, combined with flow meters and detectors, realizes full-process monitoring of media parameters and operating status. It can compare the collected parameters with preset safety thresholds, and output early warning information and execute interlock shutdown when parameters are abnormal or actuators fail, cutting off the media supply. This solves the problem of the lack of safety protection mechanisms in existing equipment, avoids the expansion of equipment failure, and prevents safety hazards during maintenance. At the same time, with the heat sink and side plate structure, it ensures the smooth completion of the maintenance process and improves the safety and reliability of equipment operation.

[0020] In summary, this solution combines an integrated detection structure, automated control, and safety interlocking protection to simultaneously achieve accurate temperature and humidity data acquisition, adaptive closed-loop control of the curing process, and safe equipment operation. It effectively solves the problems of inaccurate monitoring, manual operation, high energy consumption, and poor safety of existing equipment. While ensuring stable and compliant railway concrete sleeper curing quality, it also achieves energy saving, consumption reduction, and reliable equipment operation. Attached Figure Description

[0021] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the overall three-dimensional structure proposed in this invention; Figure 2 This is a schematic diagram of the overall three-dimensional structure of the other side proposed in this invention; Figure 3 This is a schematic diagram of the overall three-dimensional structure proposed in this invention from a bottom-view perspective; Figure 4 This is a schematic diagram of a partial three-dimensional structure on the other side of the present invention; Figure 5 The present invention proposes Figure 4 Enlarged schematic diagram of the structure at part A in the middle; Figure 6 This is a schematic diagram of the overall three-dimensional structure of the rear view portion proposed in this invention; Figure 7 This is a block diagram of the overall system connection proposed in this invention; Figure 8This is a block diagram of the fault interlocking control proposed in this invention.

[0022] The following are the components listed in the diagram: 1. Column; 2. Heat sink; 3. Control board; 4. Top plate; 5. Side plate; 6. Casters; 7. Connecting wires; 8. Solenoid valve; 9. Liquid inlet valve; 10. Steam outlet valve; 11. Display panel; 12. Mounting box; 13. Flow meter; 14. Detector; 15. Sealing cover; 16. Temperature sensor; 17. Humidity sensor; 18. Circuit board. Detailed Implementation

[0023] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0024] See Figures 1 to 8 This invention discloses an energy-saving steam curing device for railway concrete sleepers, comprising a device frame and casters 6. The device frame is composed of columns 1, a top plate 4, and a bottom plate fixedly connected together. The casters 6 are rectangularly distributed and installed on the bottom of the bottom plate. A detection mechanism for real-time monitoring of the temperature and humidity parameters of the environment in which the device is placed is fixedly installed on the top plate 4. The detection mechanism is electrically connected to a soft-circuit control unit, which is electrically connected to a solenoid valve 8, a steam ejection valve 10, a flow meter 13, a detector 14, a control board 3, and a display panel 11. The soft-circuit control unit is used to receive collected parameter data, perform data processing, generate curing control strategies, and output control commands to the corresponding actuators.

[0025] In this design, the frame provides a rigid load-bearing structure for the entire equipment, while the casters 6 at the bottom allow for flexible movement of the equipment between different maintenance stations, adapting to the operational needs of multi-station rotation maintenance in industrial production lines and multi-point maintenance on-site. The detection mechanism is directly installed on the top plate 4, with its detection end directly contacting the maintenance area environment, avoiding data distortion caused by obstructions from pipelines and the casing, and providing accurate basic data for maintenance control. The soft-connect control unit, as the core of the equipment's control, realizes fully automated control of the entire process of data acquisition, analysis, processing, and execution, replacing manual operation and eliminating control deviations caused by human experience.

[0026] Furthermore, the detection mechanism includes a mounting box 12, a temperature sensor 16, a humidity sensor 17, a circuit board 18, and a sealing cover 15. The mounting box 12 is fixedly connected to the upper surface of the top plate 4. The bottom of the mounting box 12 has a vertically downward-facing wire hole for threading wires. The temperature sensor 16 and the humidity sensor 17 are both installed through the body of the mounting box 12, and the temperature sensor 16 and the humidity sensor 17 are located on the same side of the mounting box 12 with their detection ends extending to the outside of the mounting box 12. The circuit board 18 is detachably installed inside the mounting box 12 by bolts and is electrically connected to the temperature sensor 16 and the humidity sensor 17. The sealing cover 15 is detachably closed to the top of the mounting box 12 by a fixing pin.

[0027] In this design, the mounting box 12 and the sealing cover 15 form a sealed protective cavity, which can effectively isolate the high temperature and humidity moisture and dust in the maintenance environment from corroding the internal circuit board 18 and extend the service life of electrical components. The temperature sensor 16 and the humidity sensor 17 are arranged on the same side and in the same direction, and the detection end extends synchronously to the outside of the mounting box 12, which can ensure that the two collect temperature and humidity data from the same spatial location, avoid data deviation caused by spatial location differences, and further improve monitoring accuracy. The wire hole at the bottom of the mounting box 12 adopts a vertical downward opening method, which can prevent moisture from entering the interior of the mounting box 12 along the wire and improve the sealing and protection effect.

[0028] Furthermore, an inlet valve 9, a solenoid valve 8, and a Y-shaped metal connecting pipe are also installed on the top plate 4; the inlet valve 9 is equipped with a manual adjustment structure for controlling the inlet flow rate; the solenoid valve 8 is fixedly installed at one end of the inlet valve 9 near the top plate 4; the Y-shaped metal connecting pipe is fixedly installed on one side above the top plate 4, and one end of the Y-shaped metal connecting pipe is connected to the inlet pipeline, while the other two ends are respectively fixedly installed with a flow meter 13 and a detector 14. The flow meter 13 is used to monitor the inlet flow rate, and the detector 14 is used to detect the inlet water quality or steam purity.

[0029] In this solution, the manual adjustment structure of the inlet valve 9 can realize the basic flow setting during the equipment commissioning stage, and can also realize manual emergency control when the automatic control fails; the solenoid valve 8, as the actuator of the automatic control, can receive the instructions of the soft control unit to realize the continuous adjustment of the opening degree, thereby realizing the precise control of the inlet flow rate; the Y-shaped metal connecting pipe adopts a one-inlet and two-outlet structure, which can realize flow monitoring and media quality detection simultaneously without changing the main pipeline diameter and without affecting the normal transportation of the medium, avoiding the problems of structural complexity and increased leakage points caused by adding extra pipelines, and improving the integration of the equipment structure and operational reliability.

[0030] Furthermore, a steam ejection valve 10 is fixedly installed on the other side of the Y-shaped metal connecting pipe above the top plate 4, and the steam ejection valve 10 is connected to the steam generating mechanism; a display panel 11 is fixedly installed on one end of the top plate 4, and the display panel 11 is electrically connected to the circuit board 18, the flow meter 13, and the detector 14 for real-time display of maintenance-related data.

[0031] In this solution, the steam ejection valve 10 is a continuously adjustable electric valve, which can receive instructions from the soft control unit to achieve stepless adjustment of the opening degree, thereby accurately controlling the steam output to match the steam demand of different maintenance stages; the display panel 11 adopts an industrial-grade touch screen, which can display real-time data such as the temperature and humidity of the maintenance environment, the inlet flow rate, the medium quality parameters, the valve opening degree, the maintenance time, and the equipment operating status, realizing visual monitoring of the maintenance process. At the same time, it supports operators to set maintenance parameters and switch working modes through the display panel 11.

[0032] Furthermore, heat dissipation plates 2 are fixedly installed between the columns 1 at both ends of the device frame. The heat dissipation plates 2 are made of metal. A control board 3 is fixedly installed on the outer surface of one of the heat dissipation plates 2. The control board 3 integrates a control switch and a status indicator light.

[0033] In this solution, the heat dissipation plate 2 is made of aluminum alloy or stainless steel with high thermal conductivity, which can achieve uniform and slow release of heat in the curing area during the curing and cooling stage, and avoid the temperature cracks of concrete sleepers caused by a sudden drop in temperature in the curing area. The control board 3 integrates control switches including the main power switch, emergency stop switch, and manual / automatic mode switch. The status indicator lights include running indicator light, standby indicator light, and fault indicator light, which can realize local emergency control of the equipment and intuitive display of the operating status, improving the convenience and safety of equipment operation.

[0034] Furthermore, side plates 5 are fixedly installed between the columns 1 on both sides of the device frame. The side plates 5 are used to close the sides of the device frame. A connecting wire 7 is fixedly installed on one side plate 5. One end of the connecting wire 7 is electrically connected to the control board 3 and the circuit board 18.

[0035] In this design, the side plate 5, together with the column 1, the top plate 4, and the bottom plate, form a relatively enclosed main body cavity of the equipment, which can reduce steam leakage during the maintenance process, improve steam utilization efficiency, and further achieve energy-saving effects. The connecting wire 7 uses a shielded cable, which can effectively shield electromagnetic interference in the industrial field and ensure the stability of signal transmission. At the same time, the connecting wire 7 is fixed by the side plate 5, which can avoid the problem of insulation layer damage and loose wiring caused by wire dragging, and improve the reliability of the electrical connection of the equipment.

[0036] Furthermore, the Softcom control unit includes a data acquisition module, a data preprocessing module, an adaptive maintenance control module, an instruction output module, and a human-machine interaction module. The input terminals of the data acquisition module are electrically connected to the detection mechanism, flow meter 13, detector 14, and control board 3, respectively. The output terminal of the data acquisition module is electrically connected to the input terminal of the data preprocessing module. The output terminal of the data preprocessing module is electrically connected to the input terminal of the adaptive maintenance control module. The output terminal of the adaptive maintenance control module is electrically connected to the input terminals of the instruction output module and the human-machine interaction module, respectively. The output terminal of the instruction output module is electrically connected to the solenoid valve 8, steam ejection valve 10, control board 3, and display panel 11, respectively.

[0037] It should be further noted that the Softcom control unit adopts a modular design, with each module interacting with the others via an industrial bus. This enables decoupling of the entire process—acquisition, preprocessing, control, output, and interaction—facilitating future functional upgrades and equipment maintenance. The data acquisition module synchronously acquires heterogeneous data from multiple sources, providing a comprehensive data foundation for subsequent control logic. The data preprocessing module cleans and standardizes raw data, eliminating data noise and outliers that could interfere with the control logic. The adaptive maintenance control module is the core computing unit of the Softcom control unit, enabling the dynamic generation and optimization of maintenance strategies. The command output module converts control commands into signals and amplifies their power, driving actuators to complete corresponding actions. The human-machine interaction module enables the setting of maintenance parameters, display of operational data, and input of manual commands.

[0038] Furthermore, the data acquisition module is used to collect multi-channel parameter data according to a preset cycle. The parameter data includes ambient temperature and humidity data output by the detection mechanism, liquid flow rate data output by flow meter 13, medium parameter data output by detector 14, equipment operating status data output by control board 3, and valve status feedback data output by solenoid valve 8 and steam ejection valve 10. The data preprocessing module is used to perform filtering, outlier removal, format conversion and normalization on the collected parameter data, and output the processed parameter data to the adaptive maintenance control module. The filtering process employs a moving average filtering algorithm to eliminate high-frequency random noise in the collected data. The algorithm formula is as follows: In the formula The parameter value after filtering at the k-th sampling time; The original parameter values ​​collected at the i-th sampling time; is the width of the sliding filter window, which takes a positive integer value and can be adjusted according to the sampling period; k is the sequence number of the current sampling time; the continuously collected time series data is smoothed by the sliding average filtering algorithm, which effectively filters out the instantaneous data fluctuations of the sensor caused by electromagnetic interference and steam flow disturbance in the industrial field, avoids control logic malfunctions caused by data noise, and ensures the data stability of the input control module; Outlier removal employs the Raida criterion, also known as the 3σ criterion, to identify and remove outliers from the collected data. The algorithm steps are as follows: First, calculate the arithmetic mean of the sampled data sequence. with standard deviation The formula is: In the formula, The arithmetic mean of the sampled data sequence; is the standard deviation of the sampled data sequence; M is the total number of samples in the sampled data sequence; Let j be the parameter value of the j-th sample; when the sampled data satisfies When an outlier occurs, the data is identified as an anomaly and removed. The linear interpolation result of the two adjacent valid data points is then used to replace the outlier. By setting the Laida criterion, abnormal data caused by sensor disconnection, poor contact, or instantaneous strong interference can be effectively identified, thus preventing abnormal data from entering subsequent control links and causing control strategy distortion, and ensuring the reliability of control logic.

[0039] The normalization process employs the min-max normalization method to map parameter data of different dimensions to the [0,1] interval, thereby achieving dimension unification of multi-source data. The formula is as follows: In the formula, The parameter value is represented by the normalized value; x represents the original parameter value. This indicates the minimum setting value for the corresponding maintenance stage; This indicates the maximum set value for the corresponding maintenance stage. Through normalization, the dimensional differences between different types of data such as temperature, humidity, flow rate, and media parameters can be eliminated, which facilitates the multi-parameter fusion calculation of the subsequent adaptive maintenance control module and improves the convergence speed and control accuracy of the control algorithm.

[0040] Furthermore, the adaptive maintenance control module receives preprocessed parameter data, matches it with preset sleeper maintenance stage division rules, and determines the current target maintenance stage. It retrieves the target parameter range and control weight parameters corresponding to the target stage, and, combined with real-time collected temperature and humidity change rates, medium parameters, and maintenance duration, calculates the steam supply adjustment parameters and liquid inlet adjustment parameters for the current stage. Based on the calculated adjustment parameters, it generates corresponding opening control commands, which are sent to solenoid valve 8 and steam ejection valve 10 through the command output module to adjust the opening of the corresponding valves. Simultaneously, based on the deviation between the real-time collected parameter data and the target parameter range, it dynamically updates the adjustment parameters and control commands, forming a full-cycle closed-loop control. The maintenance stage matching determination uses a multi-parameter fusion matching algorithm, combining maintenance duration and real-time environmental parameters to accurately determine the current maintenance stage. The formula is as follows: In the formula, S represents the current maintenance stage number obtained from the determination, where 1 represents the static stop stage, 2 represents the heating stage, 3 represents the constant temperature stage, and 4 represents the cooling stage; t represents the current accumulated maintenance time. This represents the midpoint of the standard maintenance duration interval corresponding to the s-th maintenance stage; T represents the real-time temperature value of the current maintenance area. H represents the set target temperature value corresponding to the s-th maintenance stage; H represents the real-time relative humidity value of the current maintenance area. This represents the target relative humidity value corresponding to the s-th maintenance stage; In this application, the steam curing of railway concrete sleepers is matched with the four core stages of cement hydration reaction. Different stages correspond to different temperature and humidity parameters and change rate requirements. This determination method can combine curing time and real-time environmental parameters to accurately match the current curing stage, avoid stage switching errors caused by cumulative deviation of curing time and fluctuation of environmental parameters, and ensure a high degree of matching between control strategy and hydration reaction process.

[0041] The valve opening adjustment adopts an incremental PID control algorithm to achieve precise closed-loop adjustment of the valve opening. Taking temperature control as an example, the algorithm formula is as follows: ; This represents the adjustment increment of the steam ejection valve 10 at the k-th sampling time; This indicates the proportional coefficient corresponding to the current maintenance stage; This represents the integral coefficient corresponding to the current maintenance stage; The coefficients represent the differential coefficients corresponding to the current maintenance stage; e(k) represents the temperature deviation value at the k-th sampling time. ,in The target temperature value at the current moment. This is the real-time temperature value at the current moment; , These represent the temperature deviation values ​​at the (k-1)th and (k-2)th sampling times, respectively. The current opening command for steam ejection valve 10 is: In the formula This represents the steam ejection valve 10 opening command value output at the kth sampling time. This represents the valve opening command value at the (k-1)th sampling time. It should be noted that for humidity control and liquid inlet flow control, the same incremental PID control logic as the above algorithm is used, only requiring the replacement of the corresponding deviation value and control coefficient. The incremental PID algorithm only outputs the opening adjustment increment, without calculating the full output, which can effectively avoid integral saturation problems. At the same time, it will not produce large opening jumps when the valve fails, improving the stability and safety of control. Different PID control coefficients correspond to different maintenance stages, which can match the control response requirements of different stages and further improve control accuracy.

[0042] To suppress overshoot of temperature and humidity change rates, a feedforward compensation stage for temperature and humidity change rates is added to the PID control, as shown in the following formula. In the formula: This represents the feedforward compensation amount at the k-th sampling time. Indicates the feedforward compensation coefficient; This indicates the actual rate of temperature change at the current moment; This indicates the permissible rate of change of the target temperature during the current maintenance phase; The final valve opening command output is the superposition of the PID control output and the feedforward compensation: This feedforward compensation mechanism can predict the trend of temperature and humidity changes in advance and adjust the valve opening in advance when the rate of temperature and humidity change approaches the limit. This effectively suppresses the overshoot of temperature and humidity, avoids internal cracks in concrete caused by excessively rapid temperature and humidity changes, and reduces the ineffective consumption of steam, thereby further improving the energy-saving effect.

[0043] Furthermore, the Softcom control unit also includes a fault warning and interlock control module. The input terminal of the fault warning and interlock control module is electrically connected to the data acquisition module, and the output terminal is electrically connected to the human-machine interaction module and the instruction output module, respectively. The fault warning and interlock control module is used to compare the acquired parameter data with the preset safety threshold range. When the parameter data exceeds the safety threshold range, or when abnormal status feedback data of the actuator is received, a warning command is generated and sent to the human-machine interaction module, and the warning information is output through the display panel 11 and the control board 3. At the same time, an interlock control command is generated to close the solenoid valve 8 and the steam ejection valve 10 through the instruction output module, cutting off the medium supply.

[0044] It should be noted that the preset safety threshold range includes upper and lower limits for temperature and humidity, upper and lower limits for liquid inlet flow, media quality limits, valve fault feedback thresholds, etc., covering the full-dimensional safety boundaries of equipment operation; the fault warning and interlock control module adopts a hierarchical warning and interlock logic, divided into two levels: Level 1 warning and Level 2 interlock shutdown. When the parameter deviation exceeds the warning threshold but does not reach the interlock threshold, Level 1 warning is triggered, only reminding the operator to check for abnormalities through the display panel 11 and fault indicator light, without triggering shutdown; when the parameter seriously exceeds the safety threshold, or when a component fault feedback is received, Level 2 interlock shutdown is triggered, immediately closing the solenoid valve 8 and steam ejection valve 10, cutting off the media supply, and locking the automatic control function of the equipment to prevent the fault from escalating and ensure the safety of the equipment and maintenance operations.

[0045] It should be noted that the multiple sets of calculation formulas described in this specific embodiment contain repeated use of letter symbols. This repeated use is only for parameter reference within the corresponding formula. The physical meaning, calculation object, and application scenario represented by the same letter in different formulas are independent of each other and are respectively adapted to different control links such as data preprocessing, maintenance stage determination, valve opening adjustment, and feedforward compensation. The specific meaning of each letter is subject to the text description under the corresponding formula item.

[0046] The working principle of this invention is as follows: After the equipment is started, the temperature sensor 16 and humidity sensor 17 in the detection mechanism collect the temperature and humidity parameters of the maintenance environment. After preliminary processing by the circuit board 18, the data is transmitted to the soft-connect control unit. The flow meter 13 and detector 14 simultaneously collect the liquid inlet flow rate and medium parameters and transmit them to the soft-connect control unit.

[0047] The Softcom control unit receives temperature, humidity, flow rate, medium, equipment status, and valve status data through the data acquisition module. After the data preprocessing module performs filtering, outlier removal, format conversion, and normalization, the data is transmitted to the adaptive maintenance control module.

[0048] The adaptive maintenance control module matches the maintenance stage based on the preprocessed data, retrieves the corresponding target parameter range and control weight, and calculates the steam supply and liquid inlet adjustment parameters by combining the temperature and humidity change rate, medium parameters and maintenance time. It generates valve opening control commands, which are transmitted to solenoid valve 8 and steam ejection valve 10 through the command output module to adjust the valve opening and realize closed-loop control of maintenance parameters.

[0049] The display panel 11 receives data transmitted from the soft-control unit and displays maintenance-related parameters in real time; the control board 3 receives control commands, switches the working status of the equipment, and outputs status indication signals.

[0050] The fault warning and interlock control module compares the collected parameters with the preset safety threshold. When the parameters exceed the threshold or abnormal feedback is received from the actuator, a warning command is generated and transmitted to the human-machine interaction module. The warning information is output through the display panel 11 and the control board 3. At the same time, an interlock control command is generated, which closes the solenoid valve 8 and the steam ejection valve 10 through the command output module, cutting off the medium supply.

[0051] During the maintenance process, the heat dissipation plate 2 conducts heat from inside the equipment, achieving a steady drop in temperature in the maintenance area; the side plate 5 encloses the side of the device frame to reduce steam leakage; the connecting wire 7 provides power and signal transmission to the control board 3, circuit board 18 and electrical components.

[0052] After maintenance is completed, the soft-control unit outputs a shutdown command, closes the solenoid valve 8 and the steam ejection valve 10, and the equipment enters the heat dissipation stage; the casters 6 are used for overall equipment movement and changing maintenance positions.

[0053] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An energy-saving railway concrete sleeper steam curing device, comprising a device frame and universal wheels (6), the device frame is composed of a vertical column (1), a top plate (4) and a bottom plate fixed connection, the universal wheels (6) are installed in a rectangular distribution at the bottom of the bottom plate, characterized in that: A detection mechanism for real-time detection of the temperature and humidity parameters of the environment where the equipment is placed is fixedly installed on the top plate (4); The detection mechanism is electrically connected to a soft-connection control unit, which is electrically connected to a solenoid valve (8), a steam ejection valve (10), a flow meter (13), a detector (14), a control board (3), and a display panel (11). The soft-connection control unit is used to receive collected parameter data, perform data processing, generate maintenance control strategies, and output control commands to the corresponding execution elements. The detection mechanism includes a mounting box (12), a temperature sensor (16), a humidity sensor (17), a circuit board (18), and a sealing cover (15). The mounting box (12) is fixedly connected to the upper surface of the top plate (4). The bottom of the mounting box (12) has a wire hole for threading wires. The temperature sensor (16) and the humidity sensor (17) are both installed through the body of the mounting box (12). The temperature sensor (16) and the humidity sensor (17) are located on the same side of the mounting box (12), and the detection end extends to the outside of the mounting box (12). The circuit board (18) is detachably installed inside the mounting box (12) by bolts and is electrically connected to the temperature sensor (16) and the humidity sensor (17). The sealing cover (15) is detachably closed on the top of the mounting box (12) by fixing pins. The top plate (4) is also equipped with an inlet valve (9), a solenoid valve (8) and a Y-shaped metal connecting pipe; the inlet valve (9) is equipped with a manual adjustment structure for controlling the inlet flow rate; the solenoid valve (8) is fixedly installed at one end of the inlet valve (9) near the top plate (4); the Y-shaped metal connecting pipe is fixedly installed on one side above the top plate (4), and one end of the Y-shaped metal connecting pipe is connected to the inlet pipeline, and the other two ends are respectively fixedly installed with a flow meter (13) and a detector (14). The flow meter (13) is used to monitor the inlet flow rate, and the detector (14) is used to detect the inlet water quality or steam purity; The soft-connect control unit includes a data acquisition module, a data preprocessing module, an adaptive maintenance control module, an instruction output module, and a human-machine interaction module; the input end of the data acquisition module is electrically connected to the detection mechanism, flow meter (13), detector (14), and control board (3), respectively; the output end of the data acquisition module is electrically connected to the input end of the data preprocessing module; the output end of the data preprocessing module is electrically connected to the input end of the adaptive maintenance control module; the output end of the adaptive maintenance control module is electrically connected to the input ends of the instruction output module and the human-machine interaction module, respectively; and the output end of the instruction output module is electrically connected to the solenoid valve (8), steam ejection valve (10), control board (3), and display panel (11), respectively. The data acquisition module is used to acquire multiple parameter data according to a preset cycle. The parameter data includes ambient temperature and humidity data output by the detection mechanism, liquid flow rate data output by the flow meter (13), medium parameter data output by the detector (14), equipment operating status data output by the control board (3), and valve status feedback data output by the solenoid valve (8) and the steam ejection valve (10). The data preprocessing module is used to perform filtering, outlier removal, format conversion and normalization on the acquired parameter data, and output the processed parameter data to the adaptive maintenance control module. The soft-control unit also includes a fault warning and interlock control module. The input end of the fault warning and interlock control module is electrically connected to the data acquisition module, and the output end is electrically connected to the human-machine interaction module and the instruction output module, respectively. The fault warning and interlock control module is used to compare the collected parameter data with the preset safety threshold range. When the parameter data exceeds the safety threshold range or when abnormal status feedback data of the actuator is received, a warning instruction is generated and sent to the human-machine interaction module. The warning information is output through the display panel (11) and the control board (3). At the same time, an interlock control instruction is generated to close the solenoid valve (8) and the steam ejection valve (10) through the instruction output module to cut off the medium supply.

2. The energy-saving railway concrete sleeper steam curing equipment according to claim 1, characterized in that, A steam ejector valve (10) is fixedly installed on the other side of the Y-shaped metal connecting pipe above the top plate (4). The steam ejector valve (10) is connected to the steam generating mechanism. A display panel (11) is fixedly installed on one end of the top plate (4). The display panel (11) is electrically connected to the circuit board (18), flow meter (13), and detector (14) for real-time display of maintenance-related data.

3. The energy-saving railway concrete sleeper steam curing equipment according to claim 1, characterized in that, Heat sinks (2) are fixedly installed between the columns (1) at both ends of the device frame. The heat sinks (2) are made of metal. A control board (3) is fixedly installed on the outer surface of one of the heat sinks (2). The control board (3) integrates a control switch and a status indicator light.

4. The energy-saving railway concrete sleeper steam curing equipment according to claim 3, characterized in that, Side plates (5) are fixedly installed between the columns (1) on both sides of the device frame. The side plates (5) are used to close the side of the device frame. A connecting wire (7) is fixedly installed on one side of the side plate (5). One end of the connecting wire (7) is electrically connected to the control board (3) and the circuit board (18).

5. The energy-saving railway concrete sleeper steam curing equipment according to claim 1, characterized in that, The adaptive maintenance control module is used to receive preprocessed parameter data, match the preset sleeper maintenance stage division rules, and determine the target stage of the current maintenance; retrieve the target parameter range and control weight parameters corresponding to the target stage, and calculate the steam supply adjustment parameters and liquid inlet adjustment parameters of the current stage by combining the real-time collected temperature and humidity change rate, medium parameters and maintenance time; generate corresponding opening control commands based on the calculated adjustment parameters, and send them to the solenoid valve (8) and steam ejection valve (10) through the command output module to adjust the opening of the corresponding valves; at the same time, based on the deviation value between the real-time collected parameter data and the target parameter range, dynamically update the adjustment parameters and control commands to form a full-cycle closed-loop control.

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