A prestressed concrete sleeper tensioning device

Abstract

The utility model relates to the technical field of civil engineering, especially a prestressed concrete sleeper tension device. The utility model provides such a prestressed concrete sleeper tension device, including base, controller, mounting bracket, connecting block, clamping structure and electric sliding rail etc., the controller is installed to the right side of base, the middle part of base is equipped with the mounting bracket of sliding type, the upper and lower sides of mounting bracket are all slidably connected with a plurality of connecting blocks, wherein, the clamping structure is equipped between the upper and lower two connecting blocks that are close to each other, and the electric sliding rail is horizontally installed on the upper portion of mounting bracket. The utility model realizes steel strand multi-point synchronous tension through the adjustable connecting block and clamping structure on the mounting bracket, eliminates uneven stress and eccentric problem, simultaneously utilizes electric sliding rail drive connecting block horizontal movement, and flexibly adjusts the clamping spacing, adapts the steel strand arrangement of different sleeper models, and significantly improves the equipment versatility and production adaptability.

Description

Technical Field

[0001] This utility model relates to the field of civil engineering technology, and in particular to a prestressed concrete sleeper tensioning device. Background Technology

[0002] In the construction of high-speed railways, heavy-haul railways and urban rail transit, prestressed concrete sleepers are an important part of the track structure. During the sleeper manufacturing process, the application of prestress is the core process. Usually, multiple prestressed steel strands or bars are stretched simultaneously by a tensioning device. After the concrete is poured and hardened, the tension is released, so that the concrete is pre-compressed, thereby significantly improving the sleeper's crack resistance and load-bearing capacity.

[0003] However, traditional tensioning equipment often employs a single-point centralized tensioning method, using one or two large hydraulic jacks to stretch the entire group of steel strands (usually 8 to 24 strands) as a whole. Since the steel strands are arranged in a rectangular or multi-row array within the mold, this method makes it difficult to ensure uniform stress on each strand, easily leading to eccentric tension. More significantly, existing devices have fixed structures and limited adjustment capabilities. Furthermore, the spacing of steel strands varies between different sleeper models, and the traditional tensioning head position is not adjustable, making it unable to adapt to various spacing arrangements. This results in poor equipment compatibility, low utilization, and reduced production efficiency.

[0004] Therefore, it is necessary to design a prestressed concrete sleeper tensioning device. Utility Model Content

[0005] In order to overcome the shortcomings of uneven tensioning and inability to adjust the spacing of traditional tensioning equipment, this utility model provides a prestressed concrete sleeper tensioning device.

[0006] The technical implementation scheme of this utility model is as follows: a prestressed concrete sleeper tensioning device includes a base, a controller, a mounting frame, connecting blocks, a clamping structure, an electric slide rail, hydraulic jacks, and a pressure sensor. The controller is installed on the right side of the base, and the mounting frame is slidably provided in the middle of the base. Multiple connecting blocks are slidably connected to the upper and lower sides of the mounting frame. A clamping structure is provided between two adjacent upper and lower connecting blocks. An electric slide rail is horizontally installed on the upper part of the mounting frame, and the connecting blocks on the upper side are slidably connected to the electric slide rail. Hydraulic jacks are installed on the left and right sides of the rear part of the base. The telescopic ends of the hydraulic jacks are connected to the mounting frame, and pressure sensors are installed on the hydraulic jacks. The controller is electrically connected to the electric slide rail, the hydraulic jacks, and the pressure sensors.

[0007] Optionally, the clamping structure includes an anchor plate, a limiting plate, anchor clips, and locking bolts. Anchor plates are fixedly connected to the opposite sides of the two connecting blocks. Each anchor plate has a slot in the middle. The limiting plate and two anchor clips are slidably provided between the two connecting blocks. Anchor clips are engaged inside the slots of the anchor plates. Multiple locking bolts are threadedly connected between the limiting plate and the adjacent anchor plate. The limiting plate abuts against the anchor clips that are close to each other.

[0008] Optionally, it also includes displacement sensors, with displacement sensors provided on both the left and right sides of the front of the base, and the displacement sensors are electrically connected to the controller.

[0009] Optionally, it also includes a protective housing and fixing bolts, with the protective housing rotatably mounted on the upper part of the base, and a fixing bolt threadedly connecting the left side of the protective housing to the base.

[0010] Optionally, the protective housing covers both the front and top sides of the base.

[0011] Alternatively, the protective shell can be made of bulletproof transparent glass. Beneficial effects

[0012] 1. The utility model achieves multi-point synchronous tensioning of steel strands through multiple sets of adjustable connecting blocks and clamping structures on the mounting frame, eliminating uneven force and eccentricity problems. At the same time, it uses electric slide rails to drive the connecting blocks to move laterally, flexibly adjusting the clamping distance to adapt to the steel strand arrangement of different sleeper models, significantly improving the equipment's versatility and production adaptability.

[0013] 2. This utility model forms a closed safety protection area through the combination structure of protective shell and fixing bolts, which effectively prevents safety accidents caused by steel strand breakage or clamp failure during tensioning, and significantly improves the safety of equipment operation. At the same time, it is made of high-strength bulletproof transparent glass, which ensures safety protection performance without affecting the operator's real-time observation of the internal tensioning process, thus balancing safety and visibility. Attached Figure Description

[0014] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0015] Figure 2 This is a schematic diagram of the unfolded structure of the protective shell component of this utility model.

[0016] Figure 3 This is a three-dimensional structural diagram of the components of this utility model, including the electric slide rail, hydraulic jack, and pressure sensor.

[0017] Figure 4 This is a three-dimensional structural diagram of the connecting block, anchor plate, and limiting plate of this utility model.

[0018] Figure 5 This is an exploded view of the clamping structure of this utility model.

[0019] The meanings of the labels in the attached diagram are as follows: 1: base, 2: controller, 3: mounting bracket, 4: connecting block, 5: anchor plate, 6: limit plate, 7: anchor clamp, 8: locking bolt, 9: electric slide rail, 10: hydraulic jack, 11: pressure sensor, 12: displacement sensor, 13: protective housing, 14: fixing bolt. Detailed Implementation

[0020] Example: A prestressed concrete sleeper tensioning device, such as Figure 1 , Figure 2 , Figure 3 and Figure 4 As shown, the system includes a base 1, a controller 2, a mounting bracket 3, connecting blocks 4, a clamping structure, an electric slide rail 9, a hydraulic jack 10, and a pressure sensor 11. The controller 2 is mounted on the right side of the base 1. The mounting bracket 3 is slidably mounted in the middle of the base 1. Multiple connecting blocks 4 are slidably connected to the upper and lower sides of the mounting bracket 3. A clamping structure is provided between two adjacent upper and lower connecting blocks 4. The electric slide rail 9 is horizontally mounted on the upper part of the mounting bracket 3. The connecting blocks 4 on the upper side are all slidably connected to the electric slide rail 9. The hydraulic jacks 10 are mounted on the left and right sides of the rear part of the base 1. The telescopic ends of the hydraulic jacks 10 are all connected to the mounting bracket 3. Pressure sensors 11 are mounted on each hydraulic jack 10. The controller 2 is electrically connected to the electric slide rail 9, the hydraulic jack 10, and the pressure sensor 11.

[0021] like Figure 4 and Figure 5 As shown, the clamping structure includes an anchor plate 5, a limiting plate 6, anchor clips 7, and locking bolts 8. Anchor plates 5 are fixedly connected to the opposite sides of the two connecting blocks 4. The anchor plates 5 are provided with holes and slots in the middle. The limiting plates 6 and two anchor clips 7 are slidably provided between the two connecting blocks 4. Anchor clips 7 are engaged inside the holes and slots of the anchor plates 5. Multiple locking bolts 8 are threadedly connected between the limiting plates 6 and the adjacent anchor plates 5. The limiting plates 6 abut against the anchor clips 7 that are close to each other.

[0022] like Figure 2 As shown, it also includes a displacement sensor 12. The displacement sensor 12 is provided on both the left and right sides of the front part of the base 1. The displacement sensor 12 is electrically connected to the controller 2.

[0023] like Figure 1 and Figure 2As shown, it also includes a protective shell 13 and fixing bolts 14. The protective shell 13 is rotatably provided on the upper part of the base 1. The left side of the protective shell 13 is threadedly connected to the base 1 with the fixing bolts 14. The coverage area of ​​the protective shell 13 includes both the front and upper sides of the base 1, and the protective shell 13 is made of bulletproof transparent glass.

[0024] In actual use, the user can control the electric slide rail 9 via the controller 2 to drive each upper connecting block 4 to move precisely laterally, achieving flexible adaptation to the clamping position of steel strands with different spacing and multi-row array distribution, meeting the steel strand layout requirements of different sleeper molds. Subsequently, the operator first inserts the anchor clamp 7 into the inner hole of the anchor plate 5, and then passes one end of the prestressed steel strand through the slots of the front and rear anchor plates 5 in sequence. At this time, the anchor clamp 7 wraps around the outer circumference of the steel strand. Then, by tightening the locking bolt 8, the limiting plate 6 is pushed to move towards the anchor plate 5, thereby pressing the anchor clamp 7, causing it to contract radially and firmly bite the steel strand, completing the clamping and fixing. This clamping structure adopts a split anchor clamp 7 and locking bolt 8, which has controllable clamping force and strong self-locking, ensuring that there is no slippage or loosening during tensioning.

[0025] After clamping, the user sets the target tension force and tensioning stroke parameters of the steel strands through controller 2, according to the model of the prestressed concrete sleeper to be produced. Then, the hydraulic jacks 10 on both sides are activated. The telescopic ends of the hydraulic jacks 10 synchronously push the mounting frame 3 forward along the base 1, causing all connecting blocks 4 and clamping structures to be tensioned synchronously, achieving multi-point synchronous tensioning of the entire group of steel strands. Because each clamping structure is independently set on the connecting block 4 and the force path is symmetrical, the eccentric force problem caused by traditional single-point concentrated tensioning is effectively avoided, significantly improving the uniformity of force on each steel strand.

[0026] During the tensioning process, the pressure sensor 11 on the hydraulic jack 10 monitors the tension force in real time and feeds the data back to the controller 2. At the same time, the displacement sensor 12 at the front of the base 1 collects the displacement of the mounting frame 3 in real time to monitor the tensioning stroke. The controller 2 performs closed-loop control on the pressure and displacement data according to the preset program to ensure that the tension force accurately reaches the set value, prevents over-tensioning or under-tensioning, and ensures the accuracy and consistency of prestress application.

[0027] To ensure operational safety, a protective shell 13 is rotatably mounted on the upper part of the base 1. It is made of high-strength bulletproof transparent glass and covers the front and upper areas of the base 1. Before tensioning, the operator rotates the protective shell 13 to the working position and locks it with the fixing bolts 14 to form a closed protective space. This effectively blocks the high-speed flying debris generated when the steel strand breaks accidentally or the clamps fail, protecting the operator's safety. Finally, after tensioning is completed, the hydraulic jack 10 retracts to release the tension. Then, the locking bolts 8 are loosened, the anchor clamps 7 are removed, and the steel strand can be pulled out from the anchor plate 5, completing one work cycle.

Claims

1. A prestressed concrete sleeper tensioning device, characterized in that, The device includes a base (1), a controller (2), a mounting bracket (3), a connecting block (4), a clamping structure, an electric slide rail (9), a hydraulic jack (10), and a pressure sensor (11). The controller (2) is installed on the right side of the base (1). The mounting bracket (3) is slidably installed in the middle of the base (1). Multiple connecting blocks (4) are slidably connected on both the upper and lower sides of the mounting bracket (3). A clamping structure is provided between the upper and lower connecting blocks (4) that are close to each other. An electric slide rail (9) is horizontally installed on the upper part of the mounting bracket (3). The connecting blocks (4) on the upper side are slidably connected to the electric slide rail (9). Hydraulic jacks (10) are installed on both the left and right sides of the rear part of the base (1). The telescopic ends of the hydraulic jacks (10) are connected to the mounting bracket (3). A pressure sensor (11) is installed on each hydraulic jack (10). The controller (2) is electrically connected to the electric slide rail (9), the hydraulic jack (10), and the pressure sensor (11).

2. A prestressed concrete sleeper tensioning device according to claim 1, characterized in that, The clamping structure includes an anchor plate (5), a limiting plate (6), an anchor clamp (7), and a locking bolt (8). Anchor plates (5) are fixed to the two connecting blocks (4) on opposite sides. The anchor plates (5) have holes and slots in the middle. The two connecting blocks (4) are slidably provided with a limiting plate (6) and two anchor clamps (7). Anchor clamps (7) are snapped into the holes and slots of the anchor plates (5). Multiple locking bolts (8) are threadedly connected between the limiting plate (6) and the adjacent anchor plates (5). The limiting plate (6) abuts against the anchor clamps (7) that are close to each other.

3. A prestressed concrete sleeper tensioning device according to claim 2, characterized in that, It also includes a displacement sensor (12). The base (1) has displacement sensors (12) on both the left and right sides of the front. The displacement sensor (12) is electrically connected to the controller (2).

4. A prestressed concrete sleeper tensioning device according to claim 3, characterized in that, It also includes a protective shell (13) and a fixing bolt (14). The protective shell (13) is rotatably provided on the upper part of the base (1). The left side of the protective shell (13) is threadedly connected to the base (1) by a fixing bolt (14).

5. A prestressed concrete sleeper tensioning device according to claim 4, characterized in that, The protective housing (13) covers both the front and top sides of the base (1).

6. A prestressed concrete sleeper tensioning device according to claim 5, characterized in that, The protective shell (13) is made of bulletproof transparent glass.

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