Intelligent sleeper production line

Abstract

The utility model provides an intelligent sleeper production line. Comprising an intelligent steel mold cleaning station, an intelligent release agent spraying station, an intelligent sleeve and steel bar mounting station, an intelligent tensioning station, a concrete distributing and vibrating station, an automatic embossing station, an intelligent and automatic curing chamber entering station, an intelligent curing station, an intelligent and automatic curing chamber exiting station and an automatic releasing station which are sequentially connected end to end to form a closed loop. An automatic wire breaking station and an intelligent overturning demolding station; the stations are connected through roller ways. The automatic sleeper production line has the advantages that production operation of sleepers is completed through the 12 intelligent automatic stations, compatibility production of XII, IIIa, IIIc, IIIQa, novel sleepers and double-block type sleepers is met at the same time, production efficiency is greatly improved, and production cost is reduced.

Description

Technical Field

[0001] This utility model belongs to the field of railway sleeper production, and in particular relates to an intelligent railway sleeper production line. Background Technology

[0002] Railway sleepers were initially made of wood. Later, with the depletion of forest resources and the increasing awareness of environmental protection, as well as the development of science and technology, some countries began to produce steel sleepers and reinforced concrete sleepers to replace wooden sleepers. However, due to the excessive metal consumption and high cost of steel sleepers, they were not widely adopted. Since the 1950s, many countries have begun to widely produce reinforced concrete sleepers.

[0003] With the development of high-speed rail in my country, the requirements for reinforced concrete sleepers are becoming increasingly stringent. The previous manual production model can no longer meet the growing demand, which necessitates an automated sleeper production line. Summary of the Invention

[0004] In view of this, the present invention aims to propose an intelligent railway sleeper production line.

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

[0006] An intelligent railway sleeper production line includes, in a closed loop, a closed loop consisting of an intelligent steel mold cleaning station, an intelligent release agent spraying station, an intelligent sleeve and rebar installation station, an intelligent tensioning station, a concrete placing and vibration station, an automatic embossing station, an intelligent automatic curing chamber entry station, an intelligent curing station, an intelligent automatic curing chamber exit station, an automatic tension release station, an automatic wire cutting station, and an intelligent flipping and demolding station.

[0007] The various workstations are connected by roller conveyors.

[0008] Furthermore, the workstations on the production line are arranged in two rows;

[0009] The intelligent tensioning station, intelligent sleeve and rebar installation station, intelligent release agent spraying station, intelligent steel mold cleaning station and intelligent flipping demolding station are arranged in the first row from left to right, one after the other.

[0010] The concrete placement and vibration station, automatic embossing station, intelligent automatic curing room station, and intelligent curing station are arranged sequentially from left to right in the second row.

[0011] The automatic wire breaking station, automatic tension release station, and intelligent automatic curing chamber exit station are all located on the right side of the intelligent curing station.

[0012] Furthermore, the automatic wire breaking station, the automatic tension release station, and the intelligent automatic curing chamber exit station are arranged sequentially from top to bottom.

[0013] Furthermore, the intelligent maintenance station includes a central maintenance chamber roller conveyor and maintenance chambers distributed along both sides.

[0014] Furthermore, the intelligent steel mold cleaning station includes an intelligent grinding automatic dust removal system; the intelligent release agent spraying station includes an automated spraying robot; the intelligent sleeve and rebar installation station includes an industrial robot; the concrete placing and vibrating station includes a concrete precision placing machine; the intelligent automatic curing chamber entry station includes an automatic hoist; the intelligent curing station includes a steam heating system, a spray cooling system, and a temperature measurement system; the intelligent automatic curing chamber exit station includes an automatic hoist; the automatic tension release station includes a tension release machine; the automatic wire cutting station includes a truss cutting machine; and the intelligent flipping demolding station includes a fully automatic rotary flipping machine.

[0015] The advantages and positive effects of this utility model are: This production line completes the production of railway sleepers through the above 12 intelligent automated workstations, and at the same time meets the compatibility production of XⅡ, Ⅲa, Ⅲc, ⅢQa and new railway sleepers and double-block railway sleepers, which greatly improves production efficiency and reduces production costs. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a flowchart illustrating the present invention.

[0018] Figure 2 This is a schematic diagram of the workstation layout of this utility model.

[0019] In the picture:

[0020] 1. Intelligent steel mold cleaning station; 2. Intelligent release agent spraying station; 3. Intelligent sleeve and rebar installation station; 4. Intelligent tensioning station; 5. Precise concrete placement and vibration station; 6. Automatic embossing station; 7. Intelligent automatic curing chamber entry station; 8. Intelligent curing station; 9. Intelligent automatic curing chamber exit station; 10. Automatic tension release station; 11. Automatic wire cutting station; 12. Intelligent flipping demolding station. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present utility model. In the absence of conflict, the embodiments and features in the embodiments of the present utility model can be combined with each other.

[0022] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0023] Secondly, this utility model is described in detail with reference to the schematic diagrams. When describing the embodiments of this utility model, for ease of explanation, the cross-sectional views illustrating the structure of the device will be partially enlarged, not according to the usual scale. Furthermore, the schematic diagrams are merely examples and should not limit the scope of protection of this utility model. In addition, in actual manufacturing, the three-dimensional spatial dimensions of length, width, and height should be included.

[0024] In the description of this utility model, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this utility model, unless otherwise stated, "a plurality of" means two or more.

[0025] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0026] like Figure 1 and Figure 2 As shown, this utility model includes a closed loop consisting of an intelligent steel mold cleaning station 1, an intelligent release agent spraying station 2, an intelligent sleeve and rebar installation station 3, an intelligent tensioning station 4, a concrete placement and vibration station 5, an automatic embossing station 6, an intelligent automatic curing chamber entry station 7, an intelligent curing station 8, an intelligent automatic curing chamber exit station 9, an automatic tension release station 10, an automatic wire breaking station 11, and an intelligent flipping demolding station 12.

[0027] The various workstations are connected by roller conveyors.

[0028] The workstations on the production line are arranged in two rows;

[0029] The intelligent tensioning station 4, intelligent sleeve and rebar installation station 3, intelligent release agent spraying station 2, intelligent steel mold cleaning station 1 and intelligent flipping and demolding station 12 are arranged in the first row from left to right.

[0030] The concrete placement and vibration station 5, the automatic embossing station 6, the intelligent automatic curing room station 7, and the intelligent curing station 8 are arranged in the second row from left to right, one after the other.

[0031] The automatic wire breaking station 11, the automatic tension release station 10, and the intelligent automatic curing chamber exit station 9 are all located on the right side of the intelligent curing station 8; the automatic wire breaking station 11, the automatic tension release station 10, and the intelligent automatic curing chamber exit station 9 are arranged in order from top to bottom.

[0032] The intelligent maintenance station 8 includes a central maintenance chamber roller conveyor and maintenance chambers distributed along both sides.

[0033] The intelligent steel mold cleaning station 1 includes an intelligent grinding and automatic dust removal system; the intelligent grinding and automatic dust removal system uses a 3D vision system to accurately position the steel mold, an industrial-grade robot to grind the inner wall and bottom of the steel mold, and a mobile dust collection device to thoroughly remove concrete residue from the steel mold.

[0034] The intelligent spraying release agent station 2 includes an automated spraying robot; the automated spraying robot senses the position of the inner cavity through sensors, and the PLC system coordinates and processes the signals to spray the inner cavity evenly. At the same time, the release agent remaining in the air is recycled in the recycling shed to avoid pollution.

[0035] The intelligent installation sleeve and rebar station 3 includes an industrial robot; the industrial robot uses a vision system to position the steel mold, automatically identifies and grabs the sleeve and screws it into the steel mold; then the robot automatically grabs the rebar group and places it in the designated position inside the steel mold.

[0036] The tensioning equipment at the intelligent tensioning station 4 automatically connects to the tensioning screw and performs tensioning. It uses a proportional valve for automatic adjustment and control. After reaching the set force value, it holds the load (1 minute) for a countdown and then automatically locks the tension.

[0037] The concrete placing and vibrating station 5 includes a precision concrete placing machine; the precision concrete placing machine uses a gravity sensor to accurately control the amount of concrete used, and operates a distributed side-opening door to uniformly place the concrete. The vibration table automatically senses the placement situation and performs frequency-divided vibration to achieve a flat bottom surface of the sleepers.

[0038] Automatic embossing station 6: The embossing cover plate automatically falls and fits into the bottom surface of the sleeper. The vibrating table starts automatically. After the set time is reached, the cover plate automatically lifts up, completing the embossing operation.

[0039] The intelligent automatic curing chamber station 7 includes an automatic hoist; the automatic hoist intelligently identifies the position of the steel mold body, locks the steel mold, slowly lifts it up, and lowers it into the curing chamber according to the set route.

[0040] The intelligent maintenance station includes a steam heating system, a spray cooling system, and a temperature measurement system, truly achieving intelligent control of the entire process of static shutdown, heating, constant temperature, and cooling.

[0041] The intelligent automatic curing chamber exit station 9 includes an automatic lifting device; the automatic lifting device intelligently identifies the position of the curing chamber and the steel mold body, locks the steel mold and slowly lifts it out of the curing chamber, and places it on the roller conveyor according to the set route.

[0042] The automatic tensioning station 10 includes a tensioning machine; the tensioning machine can automatically align the tension rod nut and realize fully automatic mechanical screw-type slow tensioning to meet the tensioning process requirements.

[0043] Automatic wire cutting station 11 includes a truss cutting machine; the truss cutting machine is used to gradually cut the prestressed steel bars in the steel mold in units of sleepers.

[0044] The intelligent flipping and demolding station 12 includes a fully automatic rotary flipping machine. This machine clamps the steel mold and flips it 180° onto the demolding table. An airbag lifts the mold, and demolding is achieved by hammering. After demolding, the mold is flipped again and placed back onto the sleeper production line. Finished sleepers are then transported by other equipment.

[0045] The entire production process, encompassing 12 steps, has achieved fully digitalized, automated, intelligent, and unmanned operation, with sleeper production orchestrated by a single intelligent control center. The intelligent production line utilizes an information management platform for digital management, enabling data acquisition and tracking, parameter adjustment, remote monitoring, and alarm handling. Information can also be monitored and accessed in real-time via a mobile app. This significantly reduces labor costs and worker fatigue, improves sleeper tensioning and release accuracy, and achieves compatible production of XⅡ, Ⅲa, Ⅲc, ⅢQa sleepers, as well as new types of sleepers and double-block sleepers.

[0046] The embodiments of this utility model have been described in detail above, but the content described is only a preferred embodiment of this utility model and should not be considered as limiting the scope of implementation of this utility model. All equivalent changes and improvements made in accordance with the claims of this utility model should still fall within the patent coverage of this utility model.

Claims

1. An intelligent railway sleeper production line, characterized in that: It includes a series of interconnected stations forming a closed loop: intelligent steel mold cleaning station, intelligent release agent spraying station, intelligent sleeve and rebar installation station, intelligent tensioning station, concrete placement and vibration station, automatic embossing station, intelligent automatic curing chamber entry station, intelligent curing station, intelligent automatic curing chamber exit station, automatic tension release station, automatic wire cutting station, and intelligent flipping demolding station. The various workstations are connected by roller conveyors.

2. The intelligent railway sleeper production line according to claim 1, characterized in that: The workstations on the production line are arranged in two rows; The intelligent tensioning station, intelligent sleeve and rebar installation station, intelligent release agent spraying station, intelligent steel mold cleaning station and intelligent flipping demolding station are arranged in the first row from left to right, one after the other. The concrete placement and vibration station, automatic embossing station, intelligent automatic curing room station, and intelligent curing station are arranged sequentially from left to right in the second row. The automatic wire breaking station, automatic tension release station, and intelligent automatic curing chamber exit station are all located on the right side of the intelligent curing station.

3. The intelligent railway sleeper production line according to claim 2, characterized in that: The automatic wire breaking station, automatic tension release station, and intelligent automatic curing chamber exit station are arranged in order from top to bottom.

4. The intelligent railway sleeper production line according to claim 1, characterized in that: The intelligent maintenance station includes a central maintenance chamber roller conveyor and maintenance chambers distributed along both sides.

5. The intelligent railway sleeper production line according to claim 1, characterized in that: The intelligent steel mold cleaning station includes an intelligent grinding and automatic dust removal system; the intelligent release agent spraying station includes an automated spraying robot; the intelligent sleeve and rebar installation station includes an industrial robot; the concrete placing and vibration station includes a precision concrete placing machine; the intelligent automatic curing chamber entry station includes an automatic hoist; the intelligent curing station includes a steam heating system, a spray cooling system, and a temperature measurement system; the intelligent automatic curing chamber exit station includes an automatic hoist; the automatic tension release station includes a tension release machine; the automatic wire cutting station includes a truss cutting machine; and the intelligent flipping and demolding station includes a fully automatic rotary flipping machine.

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