Concrete switch tie assembly type long-line pedestal method production line system

Abstract

The utility model provides a concrete switch tie assembly type long-line pedestal method production line system. The concrete switch tie assembly type long-line pedestal method production line system comprises a tensioning frame assembly device and a model assembly device. The tensioning frame assembling device comprises a rectangular frame composed of two cross beams (1) and two longitudinal beams (2), one end of the frame is provided with a tensioning end beam (3), and the other end of the frame is provided with a fixed end beam (4). The model assembling system comprises a steel mold (5) erected on the frame, and the steel mold (5) is formed by connecting three molds end to end. The assembly type long-line pedestal has the advantages that an assembly type long-line pedestal method is adopted, production efficiency and economic benefits are improved, and labor cost is saved. And splicing points are reduced, and errors are reduced. And moreover, the layout space is reduced, the labor cost is reduced, the purposes of improving the production efficiency and the economic benefits are achieved, and automatic and assembled production is realized.

Description

Technical Field

[0001] This utility model belongs to the field of concrete railway sleepers, and in particular relates to a long-line assembly line production line system for concrete turnout sleepers. Background Technology

[0002] Turnout sleepers are special sleepers used on railway turnouts. They are mainly used at the turnout traction point and allow the turnout electrical switching components to be housed within the sleeper, facilitating large-scale maintenance work. Concrete turnout sleepers are the most commonly used type worldwide. With the increasing demand for high-speed and heavy-haul railways, replacing wooden turnout sleepers with concrete ones has become the future trend for turnout sleepers.

[0003] However, existing concrete turnout sleepers are all made of short sections spliced ​​together. Too many splicing points can easily lead to poor quality control in splicing, causing errors in the overall structure and affecting efficiency. Summary of the Invention

[0004] In view of this, the present invention aims to propose a concrete turnout sleeper assembly long-line platform production line system.

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

[0006] A prefabricated long-line platform production line system for concrete turnout sleepers includes a tensioning frame assembly device and a model assembly device.

[0007] The tensioning frame assembly device includes a rectangular frame consisting of two crossbeams (1) and two longitudinal beams (2). One end of the frame is provided with a tensioning end beam (3), and the other end is provided with a fixed end beam (4).

[0008] The model assembly system includes a steel mold (5) mounted on the frame;

[0009] The steel mold (5) is made up of three mold pieces connected end to end.

[0010] Furthermore, a tensioning device is provided on the tensioning end beam.

[0011] Furthermore, the tensioning equipment includes an overall tensioning equipment and a single-strand tensioning equipment. The overall tensioning equipment uses a microcomputer-controlled tensioning jack (6) to tension the tensioning end beam simultaneously. The single-strand tensioning equipment uses a front-clamping jack for tensioning.

[0012] Furthermore, the hydraulic cylinder stroke of the overall tensioning device is 250mm, and the hydraulic cylinder is equipped with a pressure sensor.

[0013] Furthermore, a vibration device is installed at the bottom of the steel mold.

[0014] Furthermore, the vibration device vibrates by combining an insertable vibrating rod with an attached motor.

[0015] Furthermore, the steel mold is provided with embedded parts, which are fixed by positioning bolts.

[0016] Furthermore, the embedded parts include a sleeve, a side embedded nut, and an electrical nut.

[0017] Furthermore, the steel mold includes a side mold and a detachable base plate, and a sliding roller conveyor is provided at the bottom of the base plate.

[0018] Furthermore, the bottom of the frame, tensioning end beam, fixed end beam, and steel formwork is provided with supporting columns;

[0019] A maintenance tarpaulin is also installed on one side of the frame;

[0020] A pre-tensioning platform (7) is also provided at one end of the fixed end beam.

[0021] The advantages and positive effects of this utility model are:

[0022] This invention employs a prefabricated long-line platform method, improving production efficiency and economic benefits while saving labor costs. It reduces splicing points and minimizes errors. Furthermore, it reduces layout space and labor costs, achieving the goal of improving production efficiency and economic benefits, and realizing automated and prefabricated production. Attached Figure Description

[0023] 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.

[0024] Figure 1 This is a three-dimensional schematic diagram of the present invention;

[0025] Figure 2 This is a structural scale diagram showing the top view and side view of this utility model.

[0026] In the picture:

[0027] 1. Horizontal beam 2. Longitudinal beam 3. Tensioning end beam 4. Fixed end beam

[0028] 5. Steel formwork; 6. Tensioning jacks; 7. Pre-tensioning platform Detailed Implementation

[0029] 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.

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] like Figure 1 , 2 As shown, this utility model includes a tensioned frame assembly device and a model assembly device;

[0035] The tensioning frame assembly device includes a rectangular frame consisting of two crossbeams 1 and two longitudinal beams 2. One end of the frame is provided with a tensioning end beam 3, and the other end is provided with a fixed end beam 4.

[0036] The model assembly system includes a steel mold 5 mounted on the frame; the steel mold 5 is composed of three mold pieces connected end to end.

[0037] Tensioning equipment is installed on the tensioning end beam 3. The tensioning equipment includes a general tensioning device and a single-beam tensioning device. The general tensioning device uses a microcomputer-controlled tensioning jack 6 to simultaneously tension the tensioning end beam 3. The single-beam tensioning device uses a front-clamping jack for tensioning. The hydraulic cylinder of the general tensioning device has a stroke of 250mm, and the cylinder is equipped with a pressure sensor to directly read the tension force value.

[0038] A vibration device is installed at the bottom of the steel mold 5. The vibration device uses an insertable vibrator combined with an attached motor to generate vibration.

[0039] The steel mold 5 is provided with embedded parts, which are fixed by positioning bolts. The embedded parts include a sleeve, a side embedded nut, and an electrical nut.

[0040] The steel mold 5 includes a side mold and a detachable base plate (which can be replaced to suit different models of fork sleepers). The bottom of the base plate is equipped with a sliding roller conveyor, which allows the steel mold to be displaced as a whole during tensioning and untensioning, effectively reducing the possibility of rebar pulling and breaking.

[0041] The bottom of the frame, tensioning end beam 3, fixed end beam 4 and steel mold 5 are provided with supporting columns;

[0042] A maintenance tarpaulin is also installed on one side of the frame for natural covering maintenance.

[0043] One end of the fixed end beam 4 is also provided with a pretensioning platform 7.

[0044] Follow these steps to use:

[0045] 1. Clean and spray paint the steel mold:

[0046] 1. For steel molds used for the first time, wipe the working surfaces of the steel molds clean with a clean cloth to remove oil stains. For any rusty areas, use an electric wire wheel to remove it first. Do not use a metal hammer to strike the steel molds, as this may cause deformation.

[0047] 2. For steel molds that are reused, use a flat chisel to clean the residual concrete inside the mold, especially the chamfered parts, the sleeve fixing parts, and the complex surface areas such as the joint surface with the side plate. Then use a nylon broom to sweep away the loose debris on the surface, and finally use a vacuum cleaner to clean away the dust and debris.

[0048] 3. Steel molds that are loose or floating, or have incomplete or unqualified signs or number plates, or cracked welds, shall be repaired. Steel molds that meet the requirements shall be used in the next process.

[0049] 4. Prepare the release agent and water in a 1:3 ratio before the shift, stir thoroughly, and then spray it out in a mist rather than a dripping manner using a spray device. Apply the release agent evenly and in appropriate amounts. If there is excessive liquid accumulation, wipe it off with a clean brush.

[0050] 5. Before spraying, ensure that the working surface of the steel mold is dry and free of contamination. During the spraying process, clean the concrete and adhering skin inside the steel mold, especially the rounded corners and sleeve fixing parts of the steel mold.

[0051] II. Steel wire assembly and placement into the mold

[0052] 1. Before placing the wire rope into the mold, verify the number of stirrups in the wire rope assembly and ensure that the stirrups do not cross or interfere with the prestressed wires. After confirming that everything is correct, use a special lifting tool to place the wire rope assembly into the steel mold. Arrange the wire rope assembly so that the stirrups and wire-separating plates of each sleeper section are in the appropriate positions.

[0053] 2. Before installing the fixture, check its condition and clean any metal filings from the clamping plates. If cracks are found in the fixture or the threads on the clamping plates are worn, stop using it and have it checked and confirmed by the process inspector. The fixture should be tightened firmly and the gaps should be uniform during installation.

[0054] III. Tensioning

[0055] 1. The tensioning of the long-line platform adopts a combination of overall tensioning and single-strand tensioning. The overall tensioning of the prestressed steel wire is controlled by a microcomputer, and the tensioning end beam is tensioned at the same time. The single-strand tensioning is carried out by front clamping jacks.

[0056] 2. If any abnormalities are found during the tensioning process, such as steel wires crossing or interfering with other components, or steel wires detaching from the clamps, tensioning should be stopped immediately, stress relieved, and tensioning resumed only after the problem has been resolved.

[0057] IV. Installation of production process accessories and spiral reinforcement

[0058] 1. The turnout sleeper embedded parts include sleeves, side embedded nuts, and electrical nuts. The embedded parts are fixed using special positioning bolts. The embedded parts are installed correctly in the corresponding positions on the steel mold according to the drawings.

[0059] 2. During installation, ensure that the sleeve opening is tightly fitted to the steel formwork base plate, and that it is securely fixed without loosening. After installation, check for any gaps. If there are gaps, use a feeler gauge to check the height of the gap. If the gap exceeds 0.3mm, check the quality and installation of the sleeve and positioning bolts, and reinstall them.

[0060] 3. When installing the spiral reinforcement, it must not be skewed, and the spiral reinforcement that matches the sleeve should be used to maintain a uniform gap with the pre-embedded sleeve.

[0061] 4. After tensioning is completed, the stirrups are tied.

[0062] V. Concrete Preparation

[0063] 1. C60 grade concrete is used. The batching plant adjusts the batching and metering values ​​of various raw materials according to the mix proportion notification issued by the laboratory, and starts batching only after confirming that there are no errors.

[0064] 2. Concrete mixing.

[0065] VI. Concrete Pouring and Vibration Molding

[0066] 1. Before grouting, a thorough inspection should be conducted on the position, quantity, and binding of the stirrups, whether the sleeves are perpendicular to the base plate, the condition of the dry ash and debris in the model, and the installation of accessories. Only after meeting the requirements can the work team be notified to start grouting. Otherwise, the relevant work team should be notified to handle the matter until the requirements are met.

[0067] 2. After the concrete is mixed, it is transported by a truck into a concrete placing vehicle, which then supplies the concrete into the mold shell.

[0068] 3. Use two-stage or multi-layered material feeding, ensuring even and appropriate material distribution. Due to the length and arrangement of some turnout sleepers, gaps may remain in the steel mold. Be careful not to feed material into these gaps to avoid waste; if necessary, use iron plates to cover them.

[0069] 4. Start the vibrator. Before each shift, check the vibrator motor and replace it immediately if any damage is found.

[0070] 5. After leveling the end concrete, use a vibrator to compact it every 500mm. Then start the vibrating motor and finish leveling within 1 minute of starting vibration. Set the vibration time to 180 seconds. The personnel handling the concrete should pay attention to the dryness and wetness of the concrete and promptly transmit the concrete quality information to the mixing plant staff.

[0071] 6. The vibration operator must control the concrete thickness. During vibration, the fishbone shape of the steel mold should be used as a reference. If the thickness exceeds the tolerance, the concrete should be adjusted by adding or removing material.

[0072] Estimate the amount of the last batch of material before leaving get off work, and clean the transport vehicle promptly after work. Cover the poured molds with tarpaulins immediately to keep them moist.

[0073] 7. Clean up any excess material on both sides, the back, and the surface of the steel mold.

[0074] 8. After cleaning the slag and edges, cover the area with a curing tarpaulin for maintenance.

[0075] VII. Maintenance

[0076] The turnout sleeper is cured naturally, immediately after vibration molding, and covered with a direct moisture-retaining material for the concrete.

[0077] 8. Unpacking and Demolding

[0078] 1. The following method shall be used for releasing the tension: Set the tension of the large hydraulic cylinder to 2130KN, first pull up the hydraulic cylinder, quickly loosen the mechanical nut, and then slowly release the tension. Sudden release of tension is strictly prohibited.

[0079] 2. After the tension is completely released, the prestressed steel wires are cut by burning. It is strictly forbidden to cut under stress. The cutting sequence is to start from the middle part and then cut along the tensioning end to the fixed end one by one. When cutting, be careful not to damage the end of the fork sleeper.

[0080] 3. After demolding, seal the sleeve opening. All electrical nuts, embedded nuts, and connecting components must be rust-proofed and sealed; no omissions are permitted.

[0081] (10) Palletizing

[0082] Qualified products, products awaiting repair, and defective products should be stacked separately. Products awaiting repair and defective products must not be mixed with qualified products.

[0083] 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. A concrete crossing sleeper assembly type long line bed method production line system, characterized by: The utility model relates to a model assembly system and a tensioning frame assembly device. The tensioning frame assembly device comprises a rectangular frame composed of two cross beams (1) and two longitudinal beams (2), one end of the frame is provided with a tensioning end beam (3), and the other end is provided with a fixed end beam (4). The model assembly system comprises a steel mold (5) erected on the frame. The steel mold (5) is composed of three molds connected end to end.

2. The concrete switch tie assembly type long line bed method production line system according to claim 1, characterized in that: The tensioning end beam (3) is provided with a tensioning device.

3. The concrete switch tie assembly type long line bed method production line system according to claim 2, characterized in that: The tensioning device comprises a general tensioning device and a single tensioning device, the general tensioning device adopts a microcomputer-controlled tensioning jack (6) to simultaneously tension the tensioning end beam (3); the single tensioning device adopts a front clamping jack to tension.

4. The concrete switch tie assembly type long line bed method production line system according to claim 3, characterized in that: The oil cylinder stroke of the general tensioning device is 250 mm, and the oil cylinder is provided with a pressure sensor.

5. The concrete switch tie assembly, fabricated long line bed method, production line system, according to claim 1, wherein: The bottom of the steel mold (5) is provided with a vibrating device.

6. The concrete switch tie assembly, fabricated long line bed method, production line system, according to claim 5, wherein: The vibrating device is combined with an attached motor through a plug-in vibrating rod.

7. The concrete switch tie assembly, fabricated long line bed method, production line system, as recited in claim 1, c h a r a c t e r i z e d b y: The steel mold (5) is provided with a pre-embedded part, and the pre-embedded part is fixed by using a positioning bolt.

8. The concrete switch tie assembly method of producing long line seat system according to claim 7, characterized in that: The pre-embedded part comprises a sleeve, a side pre-embedded nut and an electric nut.

9. The concrete switch tie assembly, fabricated long line bed method, production line system, as recited in claim 1, c h a r a c t e r i z e d b y: The steel mold (5) comprises a side mold and a detachable bottom plate, and the bottom plate is provided with a sliding roller.

10. The concrete switch tie assembly, fabricated long line bed method, production line system, as recited in claim 1, c h a r a c t e r i z e d b y: The bottom of the frame, the tensioning end beam (3), the fixed end beam (4) and the steel mold (5) are provided with supporting columns. The frame is further provided with a maintenance tarpaulin on one side. One end of the fixed end beam (4) is further provided with a pre-tensioning platform (7).

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