Annular production line of high-speed rail beam yard

Abstract

The utility model discloses a high-speed rail beam yard annular production line which comprises a plurality of fixed pedestals, a movable integral formwork, a movable steam curing room and a track system, the track system is an annular track, and the fixed pedestals are arranged along the annular track. The movable integral formwork and the movable steam curing room are arranged on the annular track, circularly move among the fixed pedestals and are used for completing pouring and steam curing of a beam body on the fixed pedestals, the track system comprises longitudinal moving tracks and transverse moving tracks, the longitudinal moving tracks are arranged on the two sides of the fixed pedestals in parallel, and the transverse moving tracks are arranged on the two sides of the fixed pedestals in parallel. The transverse moving track is connected with the end of the longitudinal moving track, and the longitudinal moving track and the transverse moving track form an annular track. Through the arrangement of the fixed pedestal, the movable integral template, the movable steam curing room and the annular track system, the connection of multiple procedures of beam body pouring, steam curing, tension grouting and the like is optimized, the production time is shortened, and the production efficiency is improved.

Description

Technical Field

[0001] This utility model relates to the field of concrete beam construction, specifically to a circular production line for high-speed railway beam yards. Background Technology

[0002] Due to their structural importance, bridge beams are typically produced in a centralized manner to ensure production efficiency and product quality. In existing technologies, to fully utilize production space and ensure normal beam production, beam yard production lines are generally divided into six areas. The four main areas include: a pouring area, a steam curing area, a diaphragm pouring area, and a tensioning, grouting, and sealing area. In the pouring area, the beam's platform and formwork complete the concrete pouring; the steam curing area is used to steam-cur the poured beams to ensure strength enhancement; the diaphragm pouring area is responsible for pouring the diaphragms after the main beam pouring and curing; and the tensioning, grouting, and sealing area is used for tensioning, grouting, and sealing the beams, thereby forming prestress within the beam. In addition, there are two auxiliary areas: a rebar tying area for tying and storing the beam rebar jigs; and a beam storage area for storing completed beams. This zoning, to a certain extent, meets the needs of centralized and standardized bridge beam production.

[0003] However, existing technologies still have some shortcomings. In traditional production, beams are typically moved between production areas using gantry cranes. This movement is slow, and other processes cannot be performed during this time, resulting in low production efficiency, high labor intensity, and difficulty in ensuring product quality. To address these issues, existing technologies have introduced movable platforms, fixed outer molds with overall hydraulic mold closing and demolding, and fixed steam curing areas, significantly improving production efficiency and the speed of beam strength enhancement. However, this method of moving platforms via rails is mainly suitable for the production of lighter beams used in highways and municipal engineering. For high-speed railway beams, due to their large size and heavy weight (for example, a commonly used 32-meter beam can weigh thousands of tons), moving the platforms is difficult and prone to damage, which not only affects the construction period but also makes it difficult to guarantee the quality of the beams. Utility Model Content

[0004] To address the shortcomings of existing technologies, this utility model proposes a circular production line for high-speed railway beam yards, which forms an efficient and automated production process by setting up fixed platforms, movable integral templates, movable curing chambers, and a circular track system.

[0005] To achieve the above objectives, the technical solution of this utility model is as follows:

[0006] A circular production line for a high-speed railway beam yard includes fixed pedestals, movable integral templates, movable curing chambers, and a track system. The track system is a circular track. Multiple fixed pedestals are arranged along the circular track. The movable integral templates and the movable curing chambers are arranged on the circular track and move cyclically between the fixed pedestals to complete the casting and curing of the beams on the fixed pedestals.

[0007] Preferably, the track system includes a longitudinal track and a transverse track, the longitudinal track being arranged parallel to each other on both sides of the fixed platform, and the transverse track being connected to the end of the longitudinal track, the longitudinal track and the transverse track forming the circular track.

[0008] Preferably, there are four fixed bases.

[0009] Preferably, there are multiple circular tracks.

[0010] Preferably, the circular track includes a first circular track and a second circular track arranged in parallel, the first circular track and the second circular track sharing the same transverse track.

[0011] Preferably, the movable integral template is hydraulically driven.

[0012] Preferably, the outer mold support frame of the movable integral template is equipped with rollers, which cooperate with the track system.

[0013] Preferably, the mobile steam curing chamber includes a steam curing chamber structural support assembly, a drive assembly, and a steam curing assembly. The steam curing chamber structural support assembly includes a support frame, front and rear doors, and a lower connecting component. The lower connecting component is driven to rotate by an electric cylinder and is used to connect with a fixed base to form an enclosed space. The drive assembly includes wheels and a drive motor located at the bottom of the support frame. The wheels include powered rollers and unpowered rollers, and the powered rollers are driven by the drive motor. The steam curing assembly includes a steam generator, a steam connection pipe, a connector, pipes inside the steam curing chamber, and nozzles.

[0014] Preferably, the powered roller is located on the side closer to the fixed base, and the unpowered roller is located on the side farther away from the fixed base.

[0015] Preferably, a groove is provided on the ground, and the track system is fixedly installed in the groove and cooperates with the power roller. The drive component guides the mobile steam curing chamber to move along the production line through the track system.

[0016] The beneficial effects of this utility model are as follows: The circular production line at the high-speed railway beam yard, by adopting a fixed platform design, ensures the stability and safety of the beam casting process. The robust structure of the fixed platform effectively reduces the risk of collision, tilting, or overturning of the beam during production, thereby improving production safety and stability. The design of the movable integral formwork makes the mold assembly and disassembly processes more efficient and convenient, reducing manual labor intensity and avoiding the misalignment and joint problems caused by traditional assembled formwork, significantly improving the appearance quality and production consistency of the beam concrete. The circular track system realizes the assembly line production of processes such as casting, steam curing, tensioning, and grouting, significantly improving production efficiency. At the same time, the design of the movable steam curing chamber makes the steam curing process more convenient, rapidly increasing the strength of the beam concrete and shortening the production cycle. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the high-speed rail beam yard circular production line according to an embodiment of this utility model;

[0018] Figure 2 This is a schematic diagram of multiple high-speed railway beam yard circular production lines according to an embodiment of this utility model;

[0019] Figure 3 This is a front view of the mobile steam curing chamber according to an embodiment of the present invention;

[0020] Figure 4 This is a side view of the mobile steam curing chamber according to an embodiment of the present invention;

[0021] Figure 5 This is a top view of the steam generator arrangement of this utility model;

[0022] Reference numerals: 1-Fixed platform; 2-Mobile integral template; 3-Mobile steam curing chamber; 4-Rail system; 5-Beam; 6-Support frame; 7-Lower connecting component; 8-Electric cylinder; 9-Drive motor; 10-Powered roller; 11-Non-powered roller; 12-Steam generator; 13-Steam connection pipe; 14-Joint; 15-Pipe inside the steam curing chamber; 16-Nozzle; 17-Groove; 41-Longitudinal track; 42-Transverse track; 101-First fixed platform; 102-Second fixed platform; 103-Third fixed platform; 104-Fourth fixed platform. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model belong to the present utility model.

[0024] Furthermore, the described features, structures, or characteristics can be combined in any suitable manner in one or more embodiments. Numerous specific details are provided in the following description to give a thorough understanding of embodiments of this application. However, those skilled in the art will recognize that the technical solutions of this application can be practiced without one or more of the specific details, or other methods, components, apparatuses, steps, etc., can be employed. In other instances, well-known methods, apparatuses, implementations, or operations are not shown or described in detail to avoid obscuring various aspects of this application.

[0025] Please see Figure 1-5 A circular production line for high-speed railway beam yards includes fixed platforms 1, movable integral formwork 2, movable curing chambers 3, and a track system 4. The track system 4 is a circular track. Multiple fixed platforms 1 are arranged along the circular track. The movable integral formwork 2 and movable curing chambers 3 are set on the circular track and circulate between the fixed platforms 1 to complete the pouring and curing of beams 5 on the fixed platforms 1. The fixed platforms 1 adopt a robust and stable structure to provide sufficient support and ensure that the beams 5 remain stable during pouring and curing, without tilting or shifting. The circular layout of the track system 4 allows the movable integral formwork 2 and movable curing chambers 3 to circulate smoothly between the fixed platforms 1, achieving efficient connection in the production process. The design of the movable integral formwork 2 allows the formwork to move flexibly between the fixed platforms 1 to complete the pouring of beams 5; while the design of the movable curing chambers 3 allows the curing process to quickly and conveniently follow the production progress of beams 5, effectively improving the strength of the concrete of beams 5 and shortening the production cycle.

[0026] Specifically, there can be four fixed platforms 1, namely the first fixed platform 101, the second fixed platform 102, the third fixed platform 103, and the fourth fixed platform 104. According to the concrete pouring, steam curing, tensioning and grouting processes of the beam body 5, it is most economical and reasonable to equip a set of mobile integral formwork 2 with 4 fixed platforms 1, thus forming a circular beam yard production line.

[0027] The track system 4 includes a longitudinal track 41 and a transverse track 42. The longitudinal track 41 is arranged parallel to both sides of the fixed platform 1, and the transverse track 42 is connected to the end of the longitudinal track 41. The longitudinal track 41 and the transverse track 42 form a circular track 4. The longitudinal track 41 is arranged along both sides of the fixed platform 1 and is mainly used to support and guide the longitudinal movement of the movable integral template 2 and the movable steam curing chamber 3, ensuring that they can circulate smoothly between the fixed platforms 1. The transverse track 42 is connected to the end of the longitudinal track 41, and its cooperation with the longitudinal track 41 makes the track system 4 form a closed loop, ensuring the continuity and stability of the production process.

[0028] Please see Figure 2Furthermore, there are multiple annular tracks 4, including a first annular track and a second annular track arranged in parallel, sharing the same transverse track 42. This shared transverse track 42 design saves space and simplifies the structure while ensuring effective connection between different tracks. This arrangement allows the movable integral formwork 2 and the movable curing chamber 3 to move smoothly on the annular tracks 4, improving the production line's efficiency. Through this rational track layout, the production line can efficiently complete the pouring and curing processes of the beam 5, further optimizing the production process.

[0029] In this embodiment, the movable integral template 2 is hydraulically driven. The hydraulic drive makes the movement of the integral template 2 between the fixed bases 1 smoother and provides sufficient force during mold closing and disassembly, reducing the complexity and labor intensity of manual operation. Furthermore, the outer mold support frame of the movable integral template 2 is equipped with rollers, which cooperate with the track system 4 to achieve smooth movement of the movable integral template 2 on the track system 4.

[0030] The mobile steam curing chamber 3 is also mounted on a circular track, allowing it to be moved via the track system 4 to the fixed platform 1 where the beam 5 has been poured and demolded, for steam curing. The mobile steam curing chamber 3 is designed for easy movement on the track system 4, enabling rapid steam curing of the beam 5, significantly improving the strength and hardening speed of the concrete, thereby accelerating the overall production pace. This circular production line has a rational structure and efficient operation, making it suitable for large-scale production of high-speed railway beams.

[0031] Please see Figure 3-4 The mobile steam curing chamber 3 includes a steam curing chamber structural support assembly, a drive assembly, and a steam curing assembly. The steam curing chamber structural support assembly includes a support frame 6, front and rear doors, and a lower connecting member 7. The support frame 6 provides overall structural support for the steam curing chamber 3, ensuring sufficient stability during movement and use. The front and rear doors are used to enclose the internal space of the steam curing chamber 3, while facilitating the entry and exit of the beam 5. The lower connecting member 7 is driven by an electric cylinder 8 to rotate, connecting with the fixed platform 1 to form a closed steam curing space, thereby achieving a completely sealed curing environment for the beam 5. The closed steam curing space of the steam curing chamber 3 is adapted to the structure of the beam. The design of the lower connecting member 7 ensures a tight fit with the fixed platform 1, preventing steam leakage, effectively improving steam curing efficiency, and saving energy. The drive assembly includes wheels located at the bottom of the support frame 6 and a drive motor 9.

[0032] The traveling wheels include powered rollers 10 and unpowered rollers 11. Powered rollers 10 are driven by a drive motor 9, enabling the steam curing chamber 3 to move on the track system 4. Powered rollers 10 are located on the side closer to the fixed base 1, while unpowered rollers 11 are located on the side farther from the fixed base 1. The placement of powered rollers 10 ensures precise movement of the steam curing chamber 3, while unpowered rollers 11 provide auxiliary support, ensuring stability during movement. Powered rollers 10 can be connected to the lower connecting component 7 on the same support frame. The steam curing assembly includes a steam generator 12, a steam connection pipe 13, a connector 14, internal pipes 15 within the steam curing chamber, and nozzles 16. The steam generator 12 delivers steam to the steam curing chamber 3 through the steam connection pipe 13. The design of the connector 14 ensures both sealing and flexibility of the connection, accommodating minor displacements or vibrations of the steam curing chamber 3 during movement. The pipe 15 inside the steam curing chamber is used to transport steam to the nozzles 16. The nozzles 16 are evenly arranged inside the steam curing chamber 3. Through uniform steam injection, the beam 5 can obtain a uniform temperature and humidity environment during the steam curing process, thereby accelerating the improvement of concrete strength and optimizing the production cycle of the beam 5.

[0033] A groove 17 is provided on the ground, and the track system 4 is fixedly installed in the groove 17, cooperating with the power roller 10. The design of the groove 17 not only provides fixation and protection for the track system 4, but also prevents wear or contamination problems caused by exposed tracks, extending the service life of the track system 4. The drive component guides the mobile curing chamber 3 to move along the production line through the track system 4, realizing an efficient transition from one fixed platform 1 to another, providing a reliable guarantee for the smooth operation of the assembly line production mode.

[0034] In this embodiment, the high-speed railway beam yard circular production line also includes a steering system. This system employs pulley steering, a lateral transfer trolley, a translational crane, a turnout switch, or a longitudinal and transverse wheel steering device to enable the movement of the mobile integral template 2 and the mobile curing chamber 3 between the longitudinal track 41 and the transverse track 42. The diverse design of the steering system can adapt to different site layouts and production needs. For example, pulley steering is suitable for sites with limited space, while translational cranes are suitable for large-span site structures. This flexible steering method ensures that the mobile integral template 2 and the mobile curing chamber 3 can quickly and smoothly complete track switching, effectively reducing wasted production time and improving the overall efficiency of the production line.

[0035] The production method based on the above-mentioned high-speed railway beam yard circular production line includes the following steps:

[0036] S1. After the movable integral formwork 2 is positioned in the transverse movement area, it is moved to the area of ​​the first fixed platform 101. After the formwork is closed, the beam reinforcement is hoisted in as a whole, completing the pouring of concrete for beam 5. The movable integral formwork 2 smoothly transitions from the transverse movement track 42 to the longitudinal movement track 41 via the track system 4 and is accurately positioned above the first fixed platform 101. The hydraulic drive system of the movable integral formwork 2 ensures that the formwork can be accurately closed, providing a reliable operating environment for the pouring of reinforcement for beam 5.

[0037] S2, after the concrete pouring of beam 5 in the area of ​​the first fixed platform 101 is completed, the formwork is removed and the movable integral formwork 2 is moved to the area of ​​the second fixed platform 102 to begin the prefabrication of beam 5. The formwork removal operation is completed by a hydraulic system, which is fast and stable. The movable integral formwork 2 is smoothly moved to the second fixed platform 102 via the track system 4, achieving efficient connection with the next production step.

[0038] S3, after completing the beam 5 in the area of ​​the second fixed platform 102, the movable integral formwork 2 is moved to the transverse movement area and then moved to the longitudinal movement track 41 of the third fixed platform 103 and the fourth fixed platform 104 via the transverse movement track 42. The transverse movement area, with the cooperation of the steering system, ensures that the movable integral formwork 2 can smoothly complete track switching, adapt to track movement requirements in different directions, and avoid time waste caused by poor steering.

[0039] S4, sequentially moving longitudinally to the third fixed platform 103 area for pouring beam 5 and disassembling / assembling formwork, then moving to the fourth fixed platform 104 area to complete the corresponding process. During the disassembly / assembly and movement of the formwork, the mobile integral formwork 2 can maintain stable operation through the precise cooperation of the track system 4 and rollers, avoiding deviation or tilting that may affect production.

[0040] S5, the movable integral template 2 is moved from the fourth fixed platform 104 area back to the transverse area, and then moved to the first fixed platform 101 area via the transverse track 42, forming a circular production line cycle. After completing the last process, the movable integral template 2 quickly returns to its initial position, preparing for a new production cycle. Through the closed-loop design of the track system 4, the entire production process is efficiently connected, ensuring continuous production of the beam 5 and improving overall production efficiency.

[0041] This embodiment also includes the following steps: after the movable integral formwork 2 moves from the transverse area to the area of ​​the first fixed platform 101, the movable curing chamber 3 is assembled in the transverse area. The movable curing chamber 3 is guided by the track system 4, and relying on precise track design, the components are quickly assembled and positioned in the transverse area, ensuring the stability of subsequent operations. After the movable integral formwork 2 moves from the area of ​​the first fixed platform 101 to the area of ​​the second fixed platform 102, the movable curing chamber 3 is moved to the area of ​​the first fixed platform 101 to perform curing on the newly demolded beam 5. The curing system of the movable curing chamber 3 sprays steam onto the beam 5 through evenly distributed nozzles 16, forming a constant temperature and humidity environment to rapidly increase the strength of the concrete. The movement of the curing chamber 3 is coordinated with the movement of the movable integral formwork 2 to ensure that the curing process remains synchronized with the cyclical movement of the formwork. The above steps are repeated so that the movable curing chamber 3, along with the movable integral formwork 2, performs curing on the newly demolded beam 5. During this process, the mobile steam curing chamber 3 can move flexibly on the track system 4 without additional manual operation, thus improving the level of automation. Through this coordinated mode, efficient assembly-line steam curing of the beams 5 is achieved, significantly improving production efficiency while ensuring the consistency of quality for each beam and the close connection of processes. This dynamic synchronous steam curing mode not only saves production time but also reduces energy consumption, providing a reliable guarantee for the efficient operation of the beam yard.

[0042] In the above production method, the streamlined production of beam 5 is achieved through the rational connection of each step. The circular track system combined with the automated operation of the mobile integral template 2 significantly reduces manual intervention, improves production efficiency, and at the same time ensures the quality of beam 5 and the stability of the process, providing an efficient and reliable production solution for modern high-speed railway beam yards.

[0043] Please see Figure 2 To further expand production capacity and make full use of the site, a second production line can be added behind a circular production line. The two production lines share the lateral movement area and lateral movement track 42, thus saving space in the site layout and reducing the infrastructure costs required for adding new production lines. For example, the second circular production line can be arranged parallel to the first production line, forming a more efficient multi-line production mode. Depending on the size of the site, the number of circular production lines can be extended. By adding fixed platforms 1 and track systems 4, the length of the production lines can be flexibly adjusted to adapt to different production needs. Similarly, if site conditions permit, production lines can be added laterally to further expand the production scale. This scalable design not only meets current production needs but also leaves ample room for future capacity increases, providing a flexible and reliable solution for the efficient operation of the beam yard.

[0044] Please see Figure 5Furthermore, the steam connection pipe 13 includes a pre-embedded steam pipe, which is installed underground to guide steam to the side of the fixed platform 1 opposite to the steam generator 12. The steam generator 12 is installed outside the production line, for example, one steam generator 12 is installed between production lines, and one steam generator 12 can provide steam supply to two or four steam curing chambers simultaneously.

[0045] In summary, this utility model proposes a circular production line for high-speed railway beam yards, comprising a fixed platform 1, a movable integral formwork 2, a movable curing chamber 3, and a track system 4. The circular track design enables efficient movement of the beam body 5 between various production processes. Combined with the rapid mold-closing and demolding of the movable integral formwork 2 and the flexible curing operation of the movable curing chamber 3, a highly efficient and automated production process is formed. Addressing the problems of low production efficiency, high labor intensity, and difficulty in guaranteeing product quality in traditional beam yards, the fixed platform and circular track layout improve the continuity and safety of the production line. The movable integral formwork significantly reduces the burden of manual operation, and the movable curing chamber accelerates the increase in beam strength. This utility model optimizes the connection between multiple processes such as beam casting, curing, tensioning, and grouting, reducing production time, improving production efficiency, and ensuring the consistency of beam quality and appearance. Furthermore, this utility model has good scalability; production capacity can be expanded by increasing the number of circular production lines or extending the length of the production lines, or further increased by horizontally stacking production lines, fully adapting to site conditions and production needs. This utility model is applicable to the large-scale production of high-speed railway beam yards, and has important application value, especially in scenarios with high capacity requirements and strict quality standards. It provides a high-efficiency, energy-saving and safe production solution for modern beam yards and has broad prospects for promotion and application.

[0046] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Under the concept of this utility model, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of different aspects of this utility model as described above. For the sake of brevity, they are not provided in detail. Although this utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A circular production line for a high-speed railway beam yard, characterized in that, It includes a fixed platform (1), a movable integral template (2), a movable steam curing chamber (3), and a track system (4). The track system (4) is a circular track. There are multiple fixed platforms (1) arranged along the circular track. The movable integral template (2) and the movable steam curing chamber (3) are arranged on the circular track and move cyclically between each fixed platform (1) to complete the casting and steam curing of the beam (5) on the fixed platform (1).

2. The high-speed railway beam yard circular production line according to claim 1, characterized in that, The track system (4) includes a longitudinal track (41) and a transverse track (42). The longitudinal track (41) is arranged parallel to both sides of the fixed platform (1). The transverse track (42) is connected to the end of the longitudinal track (41). The longitudinal track (41) and the transverse track (42) form the circular track.

3. The high-speed railway beam yard circular production line according to claim 1 or 2, characterized in that, There are four fixed bases (1).

4. The high-speed railway beam yard circular production line according to claim 1 or 2, characterized in that, There are multiple circular tracks.

5. The high-speed railway beam yard circular production line according to claim 4, characterized in that, The circular track includes a first circular track and a second circular track arranged side by side, and the first circular track and the second circular track share the same transverse track (42).

6. The high-speed railway beam yard circular production line according to claim 5, characterized in that, The movable integral template (2) is hydraulically driven.

7. The high-speed railway beam yard circular production line according to claim 6, characterized in that, The outer mold support frame of the movable integral template (2) is equipped with rollers, which cooperate with the track system (4).

8. The high-speed railway beam yard circular production line according to claim 1, characterized in that, The mobile steam curing chamber (3) includes a steam curing chamber structural support assembly, a drive assembly, and a steam curing assembly. The steam curing chamber structural support assembly includes a support frame (6), front and rear doors, and a lower connecting member (7). The lower connecting member (7) is driven to rotate by an electric cylinder (8) and is used to connect with a fixed base (1) to form a closed space. The drive assembly includes a walking wheel and a drive motor (9) located at the bottom of the support frame (6). The walking wheel includes a powered roller (10) and a non-powered roller (11). The powered roller (10) is driven by the drive motor (9). The steam curing assembly includes a steam generator (12), a steam connecting pipe (13), a connector (14), a pipe (15) inside the steam curing chamber, and a nozzle (16).

9. The high-speed railway beam yard circular production line according to claim 8, characterized in that, The powered roller (10) is located on the side closer to the fixed base (1), and the unpowered roller (11) is located on the side away from the fixed base (1).

10. The high-speed railway beam yard circular production line according to claim 9, characterized in that, A groove (17) is provided on the ground. The track system (4) is fixedly installed in the groove (17) and cooperates with the power roller (10). The drive component guides the mobile steam curing room (3) to move along the production line through the track system (4).

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