Integral side box culvert production line

Abstract

The utility model belongs to the field of side box culvert production and manufacturing, and particularly relates to an integral type side box culvert production line which is formed by a side box culvert pouring line, a side box culvert maintenance line, a plurality of transfer trolleys and two transfer conveying lines and integrates pouring, maintenance and demolding cycle operation. The side box culvert molds run among the pouring conveying track, the maintenance conveying track and the transfer conveying line through the transfer trolley, so that the production efficiency is improved; a hopper of a material distribution vibrating machine in the side box culvert pouring line can operate above a material distribution vibrating station along a pouring opening of a side box culvert mold under the action of a position adjusting mechanism, in addition, a valve used for adjusting the size of an opening is arranged at a discharging opening of the hopper, different advancing speeds and discharging speeds can be set according to concrete in different states, and the concrete in different states can be poured into the side box culvert mold. Uniform concrete pouring is guaranteed, and gaps and cavities are eliminated. By using the integral side box culvert production line, a large amount of manual operation is not needed, the production efficiency can be improved, and the construction cost is saved.

Description

Technical Field

[0001] The present application relates to the technical field of side box culvert production and manufacturing, and in particular to an integral side box culvert production line. Background Art

[0002] With the continuous development of the economy and society, the scale of underground space development continues to expand. Large-scale and clustered tunnel construction is becoming increasingly common in sectors such as municipal engineering, water conservancy, and mining. Box culverts, which accommodate drainage pipes, pedestrians, and vehicles, are increasingly being constructed using reinforced concrete. Existing large-diameter shield tunnels are mostly single-hole, double-track tunnels. Integral side box culverts are a crucial component of the shield tunnel's sub-track structure, supporting the track slabs, trenches, drainage pipes, and other ancillary facilities. Therefore, the quality of these integral side box culverts is crucial to tunnel construction.

[0003] Traditional monolithic box culvert production lines primarily utilize a fixed pedestal method, resulting in low production efficiency and requiring extensive manual labor. Uneven concrete pouring can easily create gaps and voids, impacting the quality of the monolithic box culvert. Furthermore, mold handling is difficult, hindering production efficiency. Therefore, developing a highly automated monolithic box culvert production system to improve efficiency and reduce construction costs is a technical challenge facing those skilled in the art. Utility Model Content

[0004] The embodiment of the present application provides an integral side box culvert production line, which aims to improve the work efficiency of integral side box culvert production, enhance product quality stability, and save production costs.

[0005] To achieve the above-mentioned purpose, the present application provides an integral side box culvert production line, including a side box culvert pouring line, a side box culvert maintenance line, multiple transfer trolleys and two transfer conveyor lines;

[0006] The side box culvert pouring line includes a pouring conveying track and an integral side box culvert hoisting station, a mold cleaning and oiling station, a steel cage mold insertion station, a mold closing station, a material distribution and vibration station, and a surface finishing station sequentially arranged along the length direction of the pouring conveying track; a material distribution and vibration machine is provided on the material distribution and vibration station, and the material distribution and vibration machine includes a frame, a position adjustment mechanism arranged on the frame, a hopper arranged on the position adjustment mechanism, and a liftable vibration mechanism, the lower end of the hopper has a discharge port, and a valve is provided in the discharge port; the hopper and the vibration mechanism can run along the pouring port of the side box culvert mold above the material distribution and vibration station under the action of the position adjustment mechanism;

[0007] The side box culvert maintenance line includes an integral steam curing kiln and a curing conveying track arranged through the integral steam curing kiln. The integral steam curing kiln has an entrance for the curing conveying track to enter and an exit for the curing conveying track to exit. Both the entrance and the exit are provided with electric rolling shutter doors.

[0008] The output end of the pouring conveying track and the input end of the maintenance conveying track are connected by a transfer conveying line, and the input end of the pouring conveying track and the output end of the maintenance conveying track are connected by another transfer conveying line. Multiple transfer trolleys can operate between the pouring conveying track, the maintenance conveying track and the transfer conveying line, and the transfer trolley carries a side box culvert mold.

[0009] Optionally, the position adjustment mechanism includes a transverse linear module arranged on the frame and a longitudinal linear module arranged on the transverse linear module. The hopper and the vibrating mechanism are arranged on the longitudinal linear module and can move perpendicular to the pouring and conveying track under the action of the longitudinal linear module and move along the pouring and conveying track under the action of the transverse linear module.

[0010] Optionally, the material distribution vibrator also includes a control device, the valve is an electric valve, the electric valve, the horizontal linear module and the longitudinal linear module are all electrically connected to the control device, and the control device controls the horizontal linear module and the longitudinal linear module to control the speed of the hopper and the vibrating mechanism along the pouring port of the side box culvert mold; the control device controls the opening degree of the electric valve to control the discharge speed of the concrete.

[0011] Optionally, a stirring shaft is rotatably provided in the hopper, a stirring blade is provided on the stirring shaft, and a driving motor connected to the stirring shaft is fixed to the outer wall of the hopper.

[0012] Optionally, the vibrating mechanism includes an electric telescopic rod provided on the position adjustment mechanism and a vibrating rod provided at the end of the electric telescopic rod.

[0013] Optionally, the material distribution vibrator further includes a concrete conveying device for loading the hopper, the concrete conveying device including a material pool located on the ground on one side of the material distribution vibrating station, a concrete pump provided in the material pool, and a conveying pipe connected to the concrete pump and extending to above the hopper.

[0014] Optionally, the side box culvert pouring line and the side box culvert maintenance line are parallel and spaced apart, and the two transfer conveying lines are respectively arranged at the two ends of the side box culvert pouring line and the side box culvert maintenance line.

[0015] Optionally, the transfer conveyor line includes a skid for supporting the transfer trolley and a conveying roller bed for transferring the skid between the casting conveyor track and the maintenance conveyor track.

[0016] The beneficial effects of the integral side box culvert production line provided by the present application are as follows: compared with the existing technology, the integral side box culvert production line of the present application is composed of a side box culvert pouring line, a side box culvert curing line, multiple transfer carts and two transfer conveyor lines to form a production line integrating pouring, curing and demoulding cycles. The side box culvert mold is operated between the pouring conveyor track, the curing conveyor track and the transfer conveyor line by the transfer cart, thereby improving production efficiency. The hopper of the material distribution vibrator in the side box culvert pouring line can be operated along the pouring port of the side box culvert mold above the material distribution vibrator station under the action of the position adjustment mechanism. In addition, the discharge port of the hopper is provided with a valve for adjusting the opening size. Different travel speeds and discharge speeds can be set for concrete in different states to ensure uniform concrete pouring and eliminate gaps and voids. The use of this integral side box culvert production line does not require a lot of manual operation, can improve production efficiency and save construction costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0018] in:

[0019] Figure 1 This is a top view of an integral side box culvert production line shown in one embodiment of the present application;

[0020] Figure 2 This is a top view of a material distribution vibrator in an integral side box culvert production line shown in one embodiment of the present application;

[0021] Figure 3 This is a side view of a material distribution vibrator in an integral side box culvert production line shown in one embodiment of the present application;

[0022] Figure 4 It is a schematic diagram of a steel bar bending machine;

[0023] Figure 5 It is a schematic diagram of a CNC hoop bending machine;

[0024] Figure 6 This is a top view of the side box culvert mold.

[0025] Description of main component symbols:

[0026] 100. Side box culvert pouring line;

[0027] 110. Casting conveyor track; 1101. Integral side box culvert hoisting station; 1102. Mould cleaning and oiling station; 1103. Rebar cage moulding station; 1104. Mould closing station; 1105. Material distribution and vibration station; 1106. Finishing station;

[0028] 120. Material distribution vibrator; 121. Frame; 122. Position adjustment mechanism; 1221. Horizontal linear module; 1222. Vertical linear module; 123. Hopper; 124. Vibrating mechanism; 125. Mixing shaft; 126. Mixing blade; 127. Drive motor; 128. Concrete conveying device; 1281. Material tank; 1282. Concrete pump; 1283. Conveying pipe;

[0029] 200, side box culvert maintenance line; 210, integral steam curing kiln; 220, maintenance conveyor track;

[0030] 300, transfer trolley;

[0031] 400, transfer conveyor line; 410, skid; 420, conveyor roller bed;

[0032] 10. Side box culvert mold; 11. Mold base plate; 12. Mold body. DETAILED DESCRIPTION

[0033] To facilitate understanding of the present application, the present application will be described more fully below with reference to the accompanying drawings. The accompanying drawings illustrate preferred embodiments of the present application. However, the present application may be implemented in many other forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a more thorough and comprehensive understanding of the disclosure of the present application.

[0034] It should be noted that when an element is referred to as being “fixed on” or “disposed on” another element, it may be directly on the other element or indirectly on the other element. When an element is referred to as being “connected to” another element, it may be directly connected to the other element or indirectly connected to the other element.

[0035] It should be understood that the terms "length," "width," "up," "down," "front," "back," "left," "right," "vertical," "horizontal," "top," "bottom," "inside," "outside," and the like, indicating positions or location relationships, are based on the positions or location relationships shown in the accompanying drawings and are intended only to facilitate the description of this application and simplify the description. They do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limiting this application. In the description of this application, "plurality" means two or more, unless otherwise expressly and specifically defined.

[0036] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art to which this application pertains. The terms used herein in the specification of this application are for the purpose of describing specific embodiments only and are not intended to limit this application.

[0037] It should also be noted that, in the embodiments of the present application, the same figure mark represents the same component or the same part. For the same parts in the embodiments of the present application, the figure may only mark one of the parts or components as an example. It should be understood that the figure mark also applies to other identical parts or components.

[0038] The embodiment of the present application provides an integral side box culvert production line, such as Figure 1-Figure 3As shown, the integral side box culvert production line includes a side box culvert pouring line 100, a side box culvert maintenance line 200, multiple transfer carts 300 and two transfer conveyor lines 400. The side box culvert pouring line 100 includes a pouring conveying track 110 and an integral side box culvert hoisting station 1101, a mold cleaning and oiling station 1102, a steel cage mold insertion station 1103, a mold closing station 1104, a material distribution and vibration station 1105 and a surface finishing station 1106, which are arranged in sequence along the length direction of the pouring conveying track 110; a material distribution and vibration machine 120 is provided on the material distribution and vibration station 1105, and the material distribution and vibration machine 120 includes a frame 121, a position adjustment mechanism 122 arranged on the frame 121, and a hopper 123 and a liftable vibration mechanism 124 arranged on the position adjustment mechanism 122, the lower end of the hopper 123 has a discharge port, and a valve is provided in the discharge port; the hopper 123 and the vibration mechanism 124 can run along the pouring port of the side box culvert mold 10 above the material distribution and vibration station 1105 under the action of the position adjustment mechanism 122. The side box culvert curing line 200 includes an integral steam curing kiln 210 and a curing conveying track 220 that runs through the integral steam curing kiln 210. The integral steam curing kiln 210 has an entrance (not shown) and an exit (not shown) for the curing conveying track 220 to enter and exit. Both the entrance and exit are provided with electric rolling shutter doors (not shown). The output end of the pouring conveying track 110 is connected to the input end of the curing conveying track 220 by a transfer conveying line 400, and the input end of the pouring conveying track 110 is connected to the output end of the curing conveying track 220 by another transfer conveying line 400. Multiple transfer carts 300 can operate between the pouring conveying track 110, the curing conveying track 220, and the transfer conveying line 400. The transfer carts 300 carry the side box culvert mold 10.

[0039] It can be understood that the side box culvert casting line 100 is used for casting and producing the integral side box culvert and performing stationary maintenance and finishing operations on the integral side box culvert.

[0040] Among them, the integral side box culvert hoisting station 1101 is used for demoulding and lifting the finished integral side box culvert from the mold. The mold cleaning and oiling station 1102 is used to clean the mold and oil the mold. Cleaning the mold is to polish and clean the mold. After demoulding, some concrete will stick to the mold. If it is not cleaned, the surface of the concrete poured next time will not be smooth. Oiling means that a layer of release agent will be applied on the inner wall of the mold after cleaning to facilitate demoulding after pouring. The steel cage mold insertion station 1103 is used to hoist the prepared steel cage into the mold. The finishing station 1106 is used to smooth the concrete at the pouring port of the side box culvert mold 10.

[0041] In the embodiment of the present application, the integral side box culvert production line is composed of a side box culvert pouring line 100, a side box culvert maintenance line 200, multiple transfer carts 300, and two transfer conveyor lines 400, forming a production line integrating pouring, maintenance, and demolding cycles. The side box culvert mold 10 is operated between the pouring conveyor track 110, the maintenance conveyor track 220, and the transfer conveyor line 400 by the transfer cart 300, thereby improving production efficiency. The hopper 123 of the material distribution vibrator 120 in the side box culvert pouring line 100 can be operated along the pouring port of the side box culvert mold 10 above the material distribution vibrator station 1105 under the action of the position adjustment mechanism 122. In addition, the discharge port of the hopper 123 is provided with a valve for adjusting the opening size. Different travel speeds and discharge speeds can be set for concrete in different states to ensure uniform concrete pouring and eliminate gaps and voids. The use of this integral side box culvert production line does not require a lot of manual operation, can improve production efficiency, and save construction costs.

[0042] In one embodiment, if Figure 2-Figure 3 As shown, the position adjustment mechanism 122 in the material vibrator 120 includes a transverse linear module 1221 arranged on the frame 121 and a longitudinal linear module 1222 arranged on the transverse linear module 1221, that is, the transverse linear module 1221 and the longitudinal linear module 1222 constitute an XY-axis cross linear module, and the hopper 123 and the vibrating mechanism 124 are arranged on the longitudinal linear module 1222, and can move perpendicular to the pouring conveying track 110 under the action of the longitudinal linear module 1222, and move along the pouring conveying track 110 under the action of the transverse linear module 1221.

[0043] Furthermore, the material distribution vibrator 120 also includes a control device, the valve is an electric valve, the electric valve, the horizontal linear module 1221 and the longitudinal linear module 1222 are all electrically connected to the control device, and the control device controls the horizontal linear module 1221 and the longitudinal linear module 1222 to control the speed of the hopper 123 and the vibrating mechanism 124 along the pouring port of the side box culvert mold 10; the control device controls the opening degree of the electric valve to control the discharge speed of the concrete.

[0044] The traditional method of spreading concrete is to manually operate a gantry crane to lift the hopper 123 for pouring. Generally, several points in the mold are selected as discharge points, and a relatively large amount of concrete is placed at one time. Then, the concrete is vibrated by a vibrating rod to make the concrete flow to the surrounding area. This method may cause the stones in the concrete to be unevenly distributed, affecting the strength of the concrete. The spreading vibrator 120 in this application adopts a printing-type spreading method, that is, the hopper 123 is controlled to move at a uniform speed along the pouring port of the side box culvert mold 10 to spread the concrete. At the same time, the discharge speed is controlled by controlling the opening size of the electric valve to control the pouring thickness of each layer of concrete. This method of spreading concrete can make the concrete more uniform and improve the pouring quality of concrete to a certain extent. After each layer of concrete is poured, the concrete in different states is vibrated by controlling the vibration frequency of the vibrating mechanism 124. The function of vibration is to expel excess bubbles in the concrete during the concrete pouring process, make the concrete more dense, and improve the strength of the concrete.

[0045] In a specific embodiment, combining Figure 2-Figure 3 As shown, a stirring shaft 125 is rotatably provided in the hopper 123 , a stirring blade 126 is provided on the stirring shaft 125 , and a driving motor 127 connected to the stirring shaft 125 is fixed to the outer wall of the hopper 123 .

[0046] By providing a stirring mechanism in the hopper 123, the concrete can be stirred evenly before being discharged.

[0047] In one embodiment, if Figure 3 As shown, the vibrating mechanism 124 includes an electric telescopic rod provided on the position adjustment mechanism 122 and a vibrating rod provided at the end of the electric telescopic rod, and the vibration frequency of the vibrating rod is adjustable.

[0048] It is understandable that in other embodiments, the electric telescopic rod may also adopt a component such as an air cylinder or an oil cylinder that can control the up and down movement of the vibrating rod.

[0049] In a specific embodiment, combining Figure 2-Figure 3 As shown, the material distribution vibrator 120 also includes a concrete conveying device 128 for loading the hopper 123. The concrete conveying device 128 includes a material pool 1281 located on the ground on one side of the material distribution vibrating station 1105, a concrete pump 1282 arranged in the material pool 1281, and a conveying pipe 1283 connected to the concrete pump 1282 and extending to the top of the hopper 123.

[0050] The concrete delivery device 128 facilitates the replenishment of concrete into the hopper 123. When replenishing concrete into the hopper 123, the hopper 123 first moves to the bottom of the end of the delivery pipe 1283 away from the material pool 1281 under the action of the position adjustment mechanism 122. The concrete mixer truck then pours the concrete into the material pool 1281, starts the concrete pump 1282, and pumps the concrete in the hopper 123 into the hopper 123 through the delivery pipe 1283.

[0051] In one embodiment, if Figure 1 As shown, the side box culvert pouring line 100 and the side box culvert maintenance line 200 are parallel and spaced apart, and two transfer conveying lines 400 are respectively arranged at both ends of the side box culvert pouring line 100 and the side box culvert maintenance line 200 .

[0052] In one embodiment, if Figure 1 As shown, the transfer conveyor line 400 includes a skid 410 for supporting the transfer trolley 300 and a conveying roller 420 for transferring the skid 410 between the casting conveyor track 110 and the maintenance conveyor track 220 .

[0053] In the embodiment of this application, Figure 4-Figure 5 As shown, the shaped steel bars used in the steel cage are made by automatic bending machines and CNC hoop bending machines YT-12, which avoids errors caused by manual cutting and greatly improves production efficiency.

[0054] like Figure 6 As shown, the side box culvert mold 10 is a multi-layered structure consisting, from bottom to top, of a mold base 11 and a mold body 12. The mold base 11 is a rectangular truss mounted on a transfer cart 300. The mold body 12 consists of two layers: an outer mold and an inner mold positioned within the outer mold. The outer mold is movable on the mold base 11. Both the outer and inner molds are closed, semicircular structures composed of a combination of convex arcs and straight lines. The outer and inner molds primarily serve to confine the concrete, and their shapes and dimensions are customized according to the design dimensions of the box culvert.

[0055] The method for using the integrated side box culvert production line in this embodiment includes the following steps:

[0056] 1) Automatically lifting, cleaning, and oiling the integral side box culvert at the hoisting station 1101 and the mold cleaning and oiling station 1102 of the side box culvert casting line 100 to obtain a finished integral side box culvert and a side box culvert mold 10;

[0057] 2) The side box culvert mold 10 is carried by the transfer trolley 300 and flows from the right end to the left end of the pouring conveyor track 110;

[0058] 3) Under the control of the control device, the side box culvert mold 10 performs related process operations at the corresponding station on the pouring conveyor track 110 using the corresponding supporting equipment to complete the production of the integral side box culvert;

[0059] 4) When the side box culvert mold 10 is transferred to the left end of the pouring conveyor track 110, the skid 410 in the transfer conveyor line 400 runs to the lower left end of the pouring conveyor track 110, and the side box culvert mold 10 moves onto the skid 410 along with the transfer trolley 300. The skid 410 moves the side box culvert mold 10 to the left end of the curing conveyor track 220 of the side box culvert curing line 200, and then enters the integral steam curing kiln 210 to perform curing operations on the integral prefabricated box culvert in the side box culvert mold 10;

[0060] 5) After the curing operation is completed, the transfer trolley 300 removes the cured side box culvert mold 10 from the integral steam curing kiln 210 and transports it to the right end of the side box culvert pouring line 100 via the right transfer conveyor line 400;

[0061] 6) Repeat the above steps 1) to 5) to enter the next production maintenance operation.

[0062] The technical features of the above embodiments can be combined arbitrarily. To make the description concise, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0063] The above embodiments merely illustrate several implementation methods of the present application. While the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present application. It should be noted that a person of ordinary skill in the art may make various modifications and improvements without departing from the spirit of the present application, all of which fall within the scope of protection of the present application. Therefore, the scope of protection of the present application shall be determined by the appended claims.

Claims

1. An integral side box culvert production line, characterized in that: It includes a side box culvert pouring line, a side box culvert maintenance line, multiple transfer trolleys and two transfer conveyor lines; The side box culvert pouring line includes a pouring conveying track and an integral side box culvert hoisting station, a mold cleaning and oiling station, a steel cage mold insertion station, a mold closing station, a material distribution and vibration station, and a surface finishing station sequentially arranged along the length direction of the pouring conveying track; a material distribution and vibration machine is provided on the material distribution and vibration station, and the material distribution and vibration machine includes a frame, a position adjustment mechanism arranged on the frame, a hopper arranged on the position adjustment mechanism, and a liftable vibration mechanism, the lower end of the hopper has a discharge port, and a valve is provided in the discharge port; the hopper and the vibration mechanism can run along the pouring port of the side box culvert mold above the material distribution and vibration station under the action of the position adjustment mechanism; The side box culvert maintenance line includes an integral steam curing kiln and a curing conveying track arranged through the integral steam curing kiln. The integral steam curing kiln has an entrance for the curing conveying track to enter and an exit for the curing conveying track to exit. Both the entrance and the exit are provided with electric rolling shutter doors. The output end of the pouring conveying track and the input end of the maintenance conveying track are connected by a transfer conveying line, and the input end of the pouring conveying track and the output end of the maintenance conveying track are connected by another transfer conveying line. Multiple transfer trolleys can operate between the pouring conveying track, the maintenance conveying track and the transfer conveying line, and the transfer trolley carries a side box culvert mold.

2. The integral side box culvert production line according to claim 1 is characterized in that: The position adjustment mechanism includes a transverse linear module arranged on the frame and a longitudinal linear module arranged on the transverse linear module. The hopper and the vibrating mechanism are arranged on the longitudinal linear module and can move perpendicular to the pouring and conveying track under the action of the longitudinal linear module and move along the pouring and conveying track under the action of the transverse linear module.

3. The integral side box culvert production line according to claim 2 is characterized in that: The material distribution vibrator also includes a control device, the valve is an electric valve, the electric valve, the horizontal linear module and the longitudinal linear module are all electrically connected to the control device, the control device controls the horizontal linear module and the longitudinal linear module, thereby controlling the speed of the hopper and the vibrating mechanism along the pouring port of the side box culvert mold; the control device controls the opening degree of the electric valve to control the discharge speed of the concrete.

4. The integral side box culvert production line according to any one of claims 1 to 3, characterized in that: A stirring shaft is rotatably provided in the hopper, a stirring blade is provided on the stirring shaft, and a driving motor connected to the stirring shaft is fixed on the outer wall of the hopper.

5. The integral side box culvert production line according to any one of claims 1 to 3, characterized in that: The vibrating mechanism includes an electric telescopic rod arranged on the position adjustment mechanism and a vibrating rod arranged at the end of the electric telescopic rod.

6. The integral side box culvert production line according to any one of claims 1 to 3, characterized in that: The material distribution vibrator also includes a concrete conveying device for loading the hopper, and the concrete conveying device includes a material pool located on the ground on one side of the material distribution vibrating station, a concrete pump arranged in the material pool, and a conveying pipe connected to the concrete pump and extending to above the hopper.

7. The integral side box culvert production line according to claim 1 is characterized in that: The side box culvert pouring line and the side box culvert maintenance line are parallel and spaced apart, and the two transfer conveying lines are respectively arranged at the two ends of the side box culvert pouring line and the side box culvert maintenance line.

8. The integral side box culvert production line according to claim 1 is characterized in that: The transfer conveyor line includes a skid for supporting the transfer trolley and a conveying roller bed for transferring the skid between the casting conveyor track and the maintenance conveyor track.

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