A high-yield high-rail track plate production line
By symmetrically arranging the concrete preparation system and the track slab production system, efficient and low-cost track slab production is achieved, solving the problem of low efficiency in existing production lines. It has the ability to produce independently on one or both sides, reducing the impact of equipment failures on production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- HEJIAN YINLONG TRACK CO LTD
- Filing Date
- 2025-07-31
- Publication Date
- 2026-07-14
AI Technical Summary
Existing track slab production lines are inefficient and costly, making it difficult to meet the needs of high-speed railway construction.
Design a high-yield high-speed railway track slab production line, including a concrete preparation system, a track slab production system, a steel bar processing system, and a finished track slab storage system. The systems are symmetrically distributed along the central axis of the concrete preparation system and are shared by the concrete mixing plant. The steel bar processing system is adjacent to the track slab production system, and the finished track slab storage system is independent. The production line adopts a continuous production method to achieve continuous production of track slabs.
It improves production efficiency, has a simple structure, lower cost, avoids production stoppages caused by the failure of a single concrete mixing plant, has independent production capacity on both sides, and saves capital investment.
Smart Images
Figure CN224489577U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of high-speed rail track slabs, and in particular relates to a high-yield high-speed rail track slab production line. Background Technology
[0002] As a major infrastructure nation, China has seen rapid development in high-speed rail. As of March 2025, the total length of high-speed rail lines in operation in China reached 48,000 kilometers, ranking first in the world. Currently, even more high-speed rail lines are under construction. In high-speed rail construction, track slabs are pre-prepared and then transported directly to the construction site for assembly. As a crucial component in high-speed rail construction, the production efficiency of track slabs directly impacts the overall construction efficiency.
[0003] The efficiency of existing track slab production lines needs to be improved. Building two complete production lines directly can improve efficiency, but the cost is too high. Therefore, a low-cost, high-efficiency production line is needed. Summary of the Invention
[0004] In view of this, in order to improve production efficiency, this utility model aims to propose a high-yield high-speed rail track slab production line.
[0005] To achieve the above objectives, the technical solution of this utility model is implemented as follows:
[0006] A high-yield high-speed railway track slab production line includes a concrete preparation system, with a track slab production system, a steel bar processing system, and a finished track slab storage system on each side of the concrete preparation system.
[0007] Each of the track slab production systems is connected to a corresponding steel bar processing system and a finished track slab storage system. The concrete preparation system is located between the two track slab production systems and is connected to both track slab production systems.
[0008] Furthermore, the various systems of the production line are symmetrically distributed along the central axis of the concrete preparation system.
[0009] Furthermore, the concrete preparation system includes two concrete mixing plants arranged side by side and a sand and gravel shed;
[0010] The sand and gravel shed is connected to a concrete mixing plant via two sand and gravel conveyor belts. Each concrete mixing plant is equipped with five cylindrical silos. Each concrete mixing plant is connected to the adjacent track slab production system via a concrete conveyor line.
[0011] Furthermore, a concrete transfer line is provided between the two concrete batching plants, allowing for the transfer of concrete between them. When all equipment is operating normally, each concrete batching plant delivers concrete to the adjacent track slab production system via its corresponding concrete transfer line; if one concrete batching plant malfunctions, the other concrete batching plant can simultaneously deliver concrete to both track slab production systems.
[0012] Furthermore, the track slab production system includes 18 interconnected stations arranged in a ring: cleaning and inspection station, release agent spraying station, embedded part installation station, rebar placement station, connector installation station, RFID card opening station, tension rod installation station, automatic tensioning station, mold temperature control station, concealed inspection station, pouring and vibration station, surface finishing and edge cleaning station, curing chamber entry station, automatic curing station, curing chamber exit station, connector removal station, automatic tension release station, and automatic demolding station.
[0013] Furthermore, the rebar placement station is connected to the rebar processing system, and the processed rebar cage is placed into the formwork at this station;
[0014] The automatic demolding station is connected to the finished track slab storage system, and the demolded track slabs are transported to the finished track slab storage system for storage.
[0015] The pouring and vibration station is connected to the concrete preparation system. The mixed concrete is transported from the concrete preparation system to the concrete placing machine above the pouring and vibration station via the concrete transport line and is added as needed.
[0016] Furthermore, the steel bar processing system is located on the outer side of the upper part of the track slab production system, close to the steel bar placement station;
[0017] The finished track slab storage system is located on the outer side of the lower part of the track slab production system.
[0018] The advantages and positive effects of this utility model are: the production line has a simple structure, its production efficiency is comparable to that of two normal production lines, and both concrete mixing plants can supply concrete to the track slab production systems on both sides, avoiding the shutdown of one side and the impact on efficiency when one of them fails. Attached Figure Description
[0019] 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.
[0020] Figure 1 This is a schematic diagram of the overall structure of this utility model;
[0021] Figure 2 This is a schematic diagram of the concrete preparation system in this utility model.
[0022] In the picture:
[0023] 1. Concrete preparation system; 2. Track slab production system; 3. Reinforcing steel processing system; 4. Finished track slab storage system.
[0024] 11. Concrete mixing plant; 12. Sand and gravel shed; 13. Cylindrical silo. Detailed Implementation
[0025] 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.
[0026] 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.
[0027] 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.
[0028] 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.
[0029] 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.
[0030] like Figure 1 and Figure 2 As shown, this utility model includes a concrete preparation system 1, and on each side of the concrete preparation system 1 there is a track slab production system 2, a steel bar processing system 3, and a finished track slab storage system 4;
[0031] Each of the track slab production systems 2 is connected to the corresponding steel bar processing system 3 and finished track slab storage system 4. The concrete preparation system 1 is located between the two track slab production systems 2 and is connected to both track slab production systems 2.
[0032] The various systems of the production line are symmetrically distributed along the central axis of the concrete preparation system 1.
[0033] The concrete preparation system 1 includes two concrete mixing plants 11 arranged side by side and a sand and gravel shed 12;
[0034] The sand and gravel shed 12 is connected to a concrete mixing plant 11 via two sand and gravel conveyor belts. Each concrete mixing plant 11 is equipped with five cylindrical silos 13. Each concrete mixing plant 11 is connected to the adjacent track slab production system 2 via a concrete conveyor line.
[0035] A concrete transfer line is also provided between the two concrete batching plants 11, which can transport concrete between the two concrete batching plants 11. When the equipment is working normally, each concrete batching plant 11 transports concrete to the adjacent track slab production system 2 through the corresponding concrete transport line; when one concrete batching plant 11 fails, the other concrete batching plant 11 can transport concrete to both track slab production systems 2 at the same time.
[0036] The track slab production system 2 includes 18 interconnected stations in a ring: cleaning and inspection station, release agent spraying station, embedded part installation station, rebar placement station, connector installation station, RFID card opening station, tension rod installation station, automatic tensioning station, mold temperature control station, concealed inspection station, pouring and vibration station, surface finishing and edge cleaning station, curing room entry station, automatic curing station, curing room exit station, connector removal station, automatic tension release station, and automatic demolding station.
[0037] The 18 fixed production stations of track slab production system 2 are described in detail below:
[0038] 1. Cleaning and inspection: Use tools such as wire brushes to remove concrete residue from the mold, mainly around the pre-embedded sleeve positioning columns on the bottom surface of the mold, and use a vacuum cleaner to clean the concrete residue; check the sealing of the mold joints, and repair any gaps; check the sealing and integrity of the tension rod rubber rings, and replace them in time if there is any leakage or damage.
[0039] 2. Apply release agent: Spray release agent onto the bottom surface and inner sides of the mold. Apply undiluted release agent to the tension rods and the central bearing hole of the mold to ensure a good demolding effect. The mixing ratio and spraying thickness of the release agent are related to the brand of release agent and the climate temperature, and should be adjusted accordingly based on the demolding effect.
[0040] 3. Install embedded parts: Install the embedded sleeve on the positioning post of the sleeve on the bottom surface of the mold, and tighten it with a rubber hammer, that is, the embedded sleeve should be in close contact with the bottom surface of the mold; then install the spiral steel bar on the embedded sleeve and tighten it.
[0041] 4. Reinforcing bar placement: Place a specified number of reinforcing bar protective layer spacers at designated positions on the bottom surface of the mold. Alternatively, these spacers can be pre-positioned on the bottom surface of the reinforcing bar cage. Inside the welded or tied reinforcing bar cage, pre-place a prestressed reinforcing bar cage with anchor plates at both ends, and hoist it into the mold together, ensuring the reinforcing bar cage rests on the spacers. This guarantees that the thickness of the reinforcing bar protective layer under and around the reinforcing bar cage is within acceptable limits. This reinforcing bar placement station is connected to the reinforcing bar processing system 3, where the processed prestressed reinforcing bar cage is placed into the mold.
[0042] 5. Install connecting parts: Install threaded combination bushings at the designated positions on the bottom surface of the mold and tighten the clamping bolts; tighten the grounding terminal on the steel reinforcement cage to the side mold with bolts; tighten the lifting sleeve to the side mold with bolts.
[0043] 6. RFID card activation: The card scanner activates the RFID card inside the steel reinforcement cage, binding the mold and steel reinforcement cage information.
[0044] 7. Install tension rods: Connect the tension rods to the threaded ends of the prestressed steel bars, and simultaneously tighten the tension rods at both ends of the prestressed steel bars using tools. Note that the anchor plates must be screwed onto the root of the threads of the prestressed steel bars beforehand.
[0045] 8. Automatic tensioning: When the mold moves to the designated position, the tensioning equipment automatically aligns and tensions the mold. After reaching the set force value, it automatically locks the locking nut on the tensioning rod and the tensioning equipment returns to its original state.
[0046] 9. Mold Temperature Control: Industrial air conditioning is used to cool or heat the mold to ensure that the mold temperature meets the requirements for concrete construction. Note that this function should be activated when the mold temperature does not meet the requirements for concrete construction.
[0047] 10. Concealed Works Inspection: Before concrete pouring, a final confirmation inspection of concealed works must be conducted. This includes checking the cleanliness of the molds, the location, quantity, and tightness of embedded parts, the quality of the reinforcing steel cage, and the tensioning and locking conditions. All these must meet the requirements for concrete pouring. If any items are found to be non-compliant, they must be corrected and rectified promptly. Only after the requirements for concrete pouring are met can the next process be carried out.
[0048] 11. Pouring and Vibration: The placing boom distributes concrete in layers, and the vibrating table vibrates according to the set time and frequency. The pouring and vibration station is connected to the concrete preparation system; the mixed concrete is transported from the concrete preparation system 1 to the placing boom above the pouring and vibration station via the concrete transport line, and poured as needed.
[0049] 12. Finishing and cleaning: Finish the bottom of the concrete slab and clean the concrete residue on the edges of the mold.
[0050] 13. Entering the curing chamber: The mold is hoisted into the designated position of the designated curing chamber by the running roller conveyor.
[0051] 14. Automatic curing: The curing chamber is automatically temperature controlled according to the set curves of static stop, heating up, constant temperature, and cooling down.
[0052] 15. Exiting the curing chamber: The mold that has finished curing is lifted from the curing chamber to the designated roller conveyor position.
[0053] 16. Disassemble the connecting parts: Remove the fastening bolts of the threaded combination bushing, grounding terminal, and lifting sleeve.
[0054] 17. Automatic tension release: When the mold moves to the designated position, the tension release equipment automatically aligns and performs a slow, synchronous mechanical tension release by twisting, so that the tension rod is separated from the prestressed steel bar. After that, the tension release equipment returns to its original state.
[0055] 18. Automatic demolding: The demolding equipment uses a suction cup to contact the bottom of the track plate to generate suction force. The suction cup lifts the track plate out of the mold. The automatic demolding station is connected to the finished track plate storage system. After demolding, the track plate is transported to the finished track plate storage system 4 for storage. The track plate mold is recycled to the first step - cleaning and inspection process.
[0056] This utility model adopts a symmetrical arrangement of high-speed rail track slab production line, with the concrete mixing plant 11 in the middle using a dual-line shared method, and each side can operate independently to produce high-speed rail track slabs.
[0057] Two parallel concrete mixing plants 11 are located on either side of the central axis of the production line. The sand and gravel shed 12 is shared, and the produced concrete can be transported between the two production lines. The steel bar processing system 3 and the finished track slab storage system 4 are independently configured for each side. The track slab production system 2 consists of 18 fixed production stations. Individual molds, following a set process flow, are conveyed by roller conveyors at a certain rhythmic flow, sequentially passing through each production station in a closed-loop cycle, thus achieving continuous production of high-speed rail track slabs. The production cycle of the track slabs is equivalent to the mold turnover period.
[0058] This invention allows for single-sided production when demand is low, or simultaneous production on both sides, providing flexibility in the supply of high-speed rail track slabs. The adjacent design of the steel reinforcement processing system 3 and the track slab production system 2 reduces the transportation distance of the processed steel cages, improving production efficiency. A shared sand and gravel shed significantly saves capital investment, especially since concrete can be transported between the two production lines, avoiding production line shutdowns due to malfunctions at a single concrete mixing plant. The track slab production system uses a continuous assembly line method to produce high-speed rail track slabs; the technology is mature, the process is advanced, and the quality is reliable. The finished track slab storage area 4 is located on both sides of the perimeter of the entire production line, facilitating the loading and dispatch of finished track slabs.
[0059] 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 high-yield high-speed railway track slab production line, characterized in that: It includes a concrete preparation system, with a track slab production system, a steel bar processing system, and a finished track slab storage system on each side of the concrete preparation system; Each of the track slab production systems is connected to a corresponding steel bar processing system and a finished track slab storage system. The concrete preparation system is located between the two track slab production systems and is connected to both track slab production systems.
2. The high-yield high-speed rail track slab production line according to claim 1, characterized in that: The various systems of the production line are symmetrically distributed along the central axis of the concrete preparation system.
3. The high-yield high-speed rail track slab production line according to claim 1, characterized in that: The concrete preparation system includes two concrete mixing plants arranged side by side and a sand and gravel shed. The sand and gravel shed is connected to a concrete mixing plant via two sand and gravel conveyor belts. Each concrete mixing plant is equipped with five cylindrical silos. Each concrete mixing plant is connected to the adjacent track slab production system via a concrete conveyor line.
4. The high-yield high-speed rail track slab production line according to claim 3, characterized in that: A concrete transfer and transportation line is also set up between the two concrete mixing plants.
5. The high-yield high-speed rail track slab production line according to claim 1, characterized in that: The track slab production system comprises 18 interconnected stations arranged in a ring: cleaning and inspection station, release agent spraying station, embedded part installation station, rebar placement station, connector installation station, RFID card opening station, tension rod installation station, automatic tensioning station, mold temperature control station, concealed inspection station, pouring and vibration station, surface finishing and edge cleaning station, curing room entry station, automatic curing station, curing room exit station, connector removal station, automatic tensioning station, and automatic demolding station.
6. The high-yield high-speed rail track slab production line according to claim 5, characterized in that: The rebar placement station is connected to the rebar processing system; The automatic demolding station is connected to the finished track slab storage system; The pouring and vibration station is connected to the concrete preparation system.
7. The high-yield high-speed rail track slab production line according to claim 6, characterized in that: The steel bar processing system is located on the outer side of the upper part of the track slab production system; The finished track slab storage system is located on the outer side of the lower part of the track slab production system.