CN118664734A - Double-station filling system and method for double-block sleeper - Google Patents

Abstract

The present invention discloses a double-block rail sleeper double-station pouring system and method, which relates to the technical field of prefabricated rail sleeper components. The system includes a concrete transportation and distribution system, a first vibrating table, and a second vibrating table. A guide track is arranged between the first vibrating table and the second vibrating table. The concrete transportation and distribution system includes a horizontal transport frame and a longitudinal transport frame installed orthogonally. The horizontal transport frame is arranged above the longitudinal transport frame; a high hopper that moves horizontally and reciprocates is arranged on the horizontal transport frame, and a concrete distributor that moves longitudinally and reciprocates is arranged on the longitudinal transport frame. The discharge port of the high hopper cooperates with the feed port of each concrete distributor; the first vibrating table is fixed on the ground below the longitudinal transport frame. The present invention has a reasonable design, adopts a vertical three-dimensional layout, makes full use of space, and adopts a central control system to control the size of the discharge port and the walking speed of the concrete distributor, so as to achieve the function of precise distribution, reduce manual operation and material replenishment, and basically realize unmanned operation.

Description

Dual-block sleeper dual-station pouring system and method

Technical Field

The present invention relates to the technical field of railway and rail transit prefabricated sleeper components, and more specifically to the technical field of a double-block sleeper double-station pouring system and method.

Background Art

With the continuous development of high-speed railway technology, double-block sleepers have gradually replaced track plates and become the mainstream. Double-block sleepers have the advantages of low cost, relatively simple manufacturing process, and high degree of automation and intelligence in the manufacturing process. Therefore, double-block sleepers are widely used in high-speed railway track projects.

At present, there are many ways to pour prefabricated double-block sleepers in China. The mainstream is to manually control the opening and closing degree of the feeding port and to feed the material vertically by reciprocating along a fixed track. This method has the advantages of simple equipment, small investment, and low requirements for concrete construction performance. However, the amount of concrete is determined by the experience of the operators, and it is difficult to control the amount of concrete. The excess part is shoveled out and the insufficient part is filled manually, which requires a large number of workers and has high labor intensity.

The original production line consists of a three-station pouring and vibrating process consisting of a pouring station, a first vibration station, and a second vibration station; the double station is to integrate the pouring station and the first vibration station of the circular assembly line into one station, and then set up a second vibration station. The double-block sleeper double-station pouring system realizes precise material distribution and one-time vibration at the same time, which is convenient for the operator to control the pouring amount during pouring, thus shortening the pouring time, saving a station space and an RGV transport vehicle.

Summary of the invention

The purpose of the present invention is to solve the above technical problems and provide a double-block sleeper double-station pouring system and method.

In order to achieve the above-mentioned purpose, the present invention specifically adopts the following technical solutions:

One aspect of the present invention provides a double-block sleeper double-station pouring system, comprising a concrete transport and material distribution system arranged on a first vibrating station, a first vibrating table arranged below the first vibrating station, and a second vibrating table arranged on the second vibrating station, a guide track is arranged between the first vibrating table and the second vibrating table, and a transport trolley is arranged on the track;

The concrete transport and distribution system includes an orthogonally installed transverse transport frame and a longitudinal transport frame, wherein the transverse transport frame is arranged above the longitudinal transport frame; the transverse transport frame is provided with a high hopper capable of reciprocating laterally along the transverse transport frame, and the longitudinal transport frame is provided with a concrete distributor capable of reciprocating longitudinally along the longitudinal transport frame, and the discharge port of the high hopper cooperates with the feed port of each concrete distributor; the first vibrating table is fixed on the ground below the longitudinal transport frame, the first vibrating table and the second vibrating table are used for placing the model to be poured, and the first vibrating table cooperates with the concrete distributor.

Specifically, the double-station pouring adopts a vertical three-dimensional layout to make full use of the space. The upper part of the first vibration station is a movable high hopper, the middle part is a concrete placing machine, and the lower part is a fixed first vibration table. For the concrete placing machine, the equipment collects, organizes and quickly analyzes and calculates data, and then locks the data after collating a large amount of data on the performance status of concrete. Based on the test data, on the basis of maintaining the stability of concrete performance, the central control system is used to control the size of the discharge port and the travel speed of the concrete placing machine, so as to achieve the function of precise distribution, reduce manual operation and material replenishment, and basically realize unmanned operation.

Specific process:

Fill the concrete into the mold; the forward and backward movement of the concrete placing machine is realized by the motor drive. The drive mechanism is designed with frequency conversion control, which has the function of stable walking and adjustable walking speed. The discharging port of the distributor is composed of two spiral feeders. During the forming process, the concrete is squeezed into each model by spiral. The walking frequency is set to 45Hz. The initial opening is large and the walking speed is slow. It can complete 80% of the amount and start the initial vibration. The secondary opening is small and the walking speed is fast to complete 90%-95% of the ash placement. The walking frequency is set to 50Hz. The placing hopper is equipped with a proximity switch and a displacement sensor to prevent collision, so that safety is improved. After many tests, the concrete compaction height is controlled at 184mm~190mm, and the ash placement work can be completed twice, with the shortest time and good product appearance.

In one embodiment, the first vibration table and the second vibration table are both provided with two sets of vibration plates with vibrators for placing the model, and each vibration plate is provided with a proximity switch cooperating with the automated RGV trolley.

In one embodiment, each vibration plate is provided with two vibration motors, and the vibration frequency of each vibration motor is adjustable, and the frequency of each vibration motor is between 80 and 120 Hz.

Specifically, the vibration motor frequency is in the range of 80-120Hz, which has sufficient exciting force. Too high vibration frequency can easily lead to casing hole sinking, hole tilting and appearance quality defects in the sleeper.

In one embodiment, each concrete placing boom is provided with a proximity switch of an induction model.

In one embodiment, it also includes a concrete feeding truck for receiving concrete mixed by the mixer. The concrete feeding truck receives the concrete at the discharge port of the mixing station and automatically moves along the track to feed the high hopper.

In one embodiment, a material door is provided at the material discharge port of the concrete feeder truck, and a hydraulic cylinder for driving the material door to open and close is also provided at the material discharge port of the concrete feeder truck.

Specifically, the hydraulic cylinder drives the material door to open and directly transports the concrete to the high hopper of the material distribution system. The closed material transportation avoids material spillage and material segregation. The concrete feeder automatically docks with the concrete mixer and high hopper without manual operation.

In one embodiment, the transport vehicle is an automated RGV vehicle.

In one embodiment, a lifting cylinder is provided on the RGV trolley.

Specifically, the model is transported to the vibration station by the RGV trolley, and the lifting cylinder of the trolley descends to drop the model onto the first vibration table with four columns. After the proximity switch on the first vibration table senses that the model has fallen into place, the material is placed, and the vibration button is activated when the ash volume reaches 80%.

A second aspect of the present invention provides a dual-block sleeper dual-station pouring method, using the dual-block sleeper dual-station pouring system described above, comprising the following steps:

S1. Use the automated RGV trolley to transport the model to the fixed vibration table, and place it accurately on the vibration table under the action of the proximity switch;

S2. Unload the concrete in the high hopper into the automatic concrete placing machine in advance, and then start the one-button automatic concrete placing program. The automatic concrete placing machine automatically discharges the material at the set walking frequency. When it reaches the end of the model, the concrete starts to vibrate when it reaches 80% of the height in the model.

S3, the concrete is quickly vibrated and the automatic concrete placing machine turns back to start the second concrete placing under the action of the displacement sensor and proximity switch, achieving the simultaneous completion of concrete placing and the first vibration;

S4, the RGV trolley transports the poured model to the second vibration station, and uses the set frequency and vibration time to complete the secondary vibration. The RGV trolley then moves the next model to the first vibration station under the control of the central control system of the vacated first vibration station;

S5. Repeat steps S1 to S4 to form a flow operation, which greatly improves the injection efficiency.

Specifically, the vibration time and frequency are determined by experiments: the first vibration frequency is set to 80Hz, 85Hz, 90Hz, and the vibration time is 60s, 70s, 80s, 90s; the second vibration frequency is set to 100Hz, 110Hz, 115Hz, and the vibration time is 70s, 80s, 90s. According to these parameters, the casting is steamed, demolded, and the appearance quality of the product is observed. After three months of experimental analysis and summary, it is concluded that the first vibration is 90Hz, the vibration time is 80s, which just completes the concrete spreading, and the second vibration is 110Hz, the vibration time is 90s, the product appearance is better, there are fewer bubbles, and no over-vibration water lines appear. The whole mold casting time is (5~6)min, and the water flow rhythm is good.

The beneficial effects of the present invention are as follows:

1. Compared with the existing technology, this solution has significant beneficial effects. First, it saves a workstation and shortens the pouring workstation time, speeds up the flow rhythm, and reduces the pouring time from the original 8 minutes to less than 6 minutes, saving 2 minutes; secondly, it reduces 3 operators and reduces labor intensity; then it achieves precise and continuous material distribution, improves the integrity and continuity of product pouring, improves the appearance quality of the product, and eliminates the waste of concrete. The working degree selection of one-click concrete distribution can match the walking frequency and number of the concrete distributor, as well as the frequency selection of double-station variable frequency vibration and the matching of vibration time.

2. The double-station pouring adopts a vertical three-dimensional layout to make full use of the space. For the concrete placing machine, the equipment collects, organizes and quickly analyzes and calculates data, and then locks the data after collating a large amount of data on the performance status of concrete. Based on the test data, on the basis of maintaining the stability of concrete performance, the central control system is used to control the size of the discharge port and the walking speed of the concrete placing machine, so as to achieve the function of precise placement, reduce manual operation and material replenishment, and basically realize unmanned operation.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use in the embodiments will be briefly introduced below. It should be understood that the following drawings only show certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other related drawings can be obtained based on these drawings without paying creative work.

Fig. 1 is a schematic structural diagram of the present invention;

FIG2 is a schematic diagram of a partial structure of FIG1 ;

Figure numerals: 1-transverse transport frame, 2-longitudinal transport frame, 3-concrete placing boom, 4-high hopper, 5-first vibrating table, 6-second vibrating table.

DETAILED DESCRIPTION

In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

It should be noted that similar reference numerals and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further defined and explained in the subsequent drawings. In addition, the terms "first", "second", etc. are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

In the description of the embodiments of the present invention, it should be noted that the terms "inside", "outside", "upper", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, or are the orientations or positional relationships in which the inventive product is usually placed when used. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

Example 1

As shown in FIGS. 1 to 2 , this embodiment provides a dual-block sleeper dual-station pouring system according to one aspect of the present invention, comprising a concrete transport and material distribution system arranged on a first vibrating station, a first vibrating table 5 arranged below the first vibrating station, and a second vibrating table 6 arranged on the second vibrating station, a guide track is arranged between the first vibrating table 5 and the second vibrating table 6, and a transport trolley is arranged on the track;

The concrete transport and distribution system includes a transverse transport frame 1 and a longitudinal transport frame 2 which are orthogonally installed. The transverse transport frame 1 is erected above the longitudinal transport frame 2. The transverse transport frame 1 is provided with a high hopper 4 which can reciprocate laterally along the transverse transport frame 1. The longitudinal transport frame 2 is provided with a concrete distributor 3 which can reciprocate longitudinally along the longitudinal transport frame 2. The discharge port of the high hopper 4 cooperates with the feed port of each concrete distributor 3. The first vibrating table 5 is fixed on the ground below the longitudinal transport frame 2. The first vibrating table 5 and the second vibrating table 6 are used to place the model to be poured. The first vibrating table 5 cooperates with the concrete distributor 3.

Specifically, the double-station pouring adopts a vertical three-dimensional layout to make full use of the space. The upper part of the first vibration station is a movable high hopper 4, the middle part is a concrete distributor 3, and the lower part is a fixed first vibration table 5. For the concrete distributor 3, the equipment collects, organizes and quickly analyzes and calculates data, and then locks the data after collating a large amount of data on the performance status of concrete. Based on the test data, on the basis of maintaining the stability of concrete performance, the central control system is used to control the size of the discharge port and the walking speed of the concrete distributor 3, so as to achieve the function of precise distribution, reduce manual operation and material replenishment, and basically realize unmanned operation.

Specific process:

Fill the concrete into the mold; the forward and backward movement of the concrete distributor 3 is realized by the motor drive, and the drive mechanism is designed with frequency conversion control, which has the function of stable movement and adjustable walking speed. The discharging port of the distributor is composed of two spiral feeders. During the forming process, the concrete is squeezed into each model by spirals. The walking frequency is set to 45Hz. The initial opening is large and the walking speed is slow. It can complete 80% of the amount and start the initial vibration. The secondary opening is small and the walking speed is fast to complete 90%-95% of the ash placement. The walking frequency is set to 50Hz. The distribution hopper is equipped with a proximity switch and a displacement sensor to prevent collision, so that safety is improved. After many tests, the concrete compaction height is controlled at 184mm~190mm, and the ash placement work can be completed twice, with the shortest time and good product appearance.

Example 2

As shown in FIGS. 1 to 2 , this embodiment provides a dual-block sleeper dual-station pouring system according to one aspect of the present invention, comprising a concrete transport and material distribution system arranged on a first vibrating station, a first vibrating table 5 arranged below the first vibrating station, and a second vibrating table 6 arranged on the second vibrating station, a guide track is arranged between the first vibrating table 5 and the second vibrating table 6, and a transport trolley is arranged on the track;

The concrete transport and distribution system includes a transverse transport frame 1 and a longitudinal transport frame 2 which are orthogonally installed. The transverse transport frame 1 is erected above the longitudinal transport frame 2. The transverse transport frame 1 is provided with a high hopper 4 which can reciprocate laterally along the transverse transport frame 1. The longitudinal transport frame 2 is provided with a concrete distributor 3 which can reciprocate longitudinally along the longitudinal transport frame 2. The discharge port of the high hopper 4 cooperates with the feed port of each concrete distributor 3. The first vibrating table 5 is fixed on the ground below the longitudinal transport frame 2. The first vibrating table 5 and the second vibrating table 6 are used to place the model to be poured. The first vibrating table 5 cooperates with the concrete distributor 3.

The first vibration table 5 and the second vibration table 6 are both provided with two sets of vibration plates with vibrators for placing the models, and each vibration plate is provided with a proximity switch cooperating with the automated RGV trolley.

Each vibration plate is provided with two vibration motors, and the vibration frequency of each vibration motor is adjustable, and the frequency of each vibration motor is between 80 and 120 Hz.

Specifically, the vibration motor frequency is in the range of 80-120Hz, which has sufficient exciting force. Too high vibration frequency can easily lead to casing hole sinking, hole tilting and appearance quality defects in the sleeper.

Each concrete placing boom 3 is provided with a proximity switch of an induction model.

Example 3

As shown in FIGS. 1 to 2 , this embodiment provides a dual-block sleeper dual-station pouring system according to one aspect of the present invention, comprising a concrete transport and material distribution system arranged on a first vibrating station, a first vibrating table 5 arranged below the first vibrating station, and a second vibrating table 6 arranged on the second vibrating station, a guide track is arranged between the first vibrating table 5 and the second vibrating table 6, and a transport trolley is arranged on the track;

The concrete transport and distribution system includes a transverse transport frame 1 and a longitudinal transport frame 2 which are orthogonally installed. The transverse transport frame 1 is erected above the longitudinal transport frame 2. The transverse transport frame 1 is provided with a high hopper 4 which can reciprocate laterally along the transverse transport frame 1. The longitudinal transport frame 2 is provided with a concrete distributor 3 which can reciprocate longitudinally along the longitudinal transport frame 2. The discharge port of the high hopper 4 cooperates with the feed port of each concrete distributor 3. The first vibrating table 5 is fixed on the ground below the longitudinal transport frame 2. The first vibrating table 5 and the second vibrating table 6 are used to place the model to be poured. The first vibrating table 5 cooperates with the concrete distributor 3.

The utility model also comprises a concrete feeding vehicle for receiving concrete mixed by the mixer. The concrete feeding vehicle receives the concrete at the discharge port of the mixing station, automatically moves along the track, and feeds the high hopper 4 with the concrete.

The discharge port of the concrete feeder truck is provided with a material door, and the discharge port of the concrete feeder truck is also provided with a hydraulic cylinder for driving the material door to open and close.

Specifically, the hydraulic cylinder drives the material door to open and directly transports the concrete to the high hopper 4 of the material distribution system. The closed material transportation avoids material spillage and material segregation; the concrete feeder automatically docks with the concrete mixer and the high hopper 4 without manual operation.

The transport vehicle is an automated RGV vehicle.

The RGV trolley is equipped with a lifting cylinder.

Specifically, the model is transported to the vibration station by the RGV trolley, and the lifting cylinder of the trolley descends to drop the model onto the first vibration table 5 with four columns. After the proximity switch on the first vibration table 5 senses that the model has fallen into place, the material is placed, and the vibration button is started after the ash volume reaches 80%.

Example 4

This embodiment provides a double-block sleeper double-station pouring method, which uses the above-mentioned double-block sleeper double-station pouring system and includes the following steps:

S1. Use the automated RGV trolley to transport the model to the fixed vibration table, and place it accurately on the vibration table under the action of the proximity switch;

S2, unload the concrete in the high hopper 4 into the automatic concrete placing machine in advance, and then start the one-key automatic concrete placing program. The automatic concrete placing machine automatically discharges the material at the set walking frequency. When the material reaches the end of the model and reaches 80% of the height in the model, it starts to vibrate.

S3, the concrete is quickly vibrated and the automatic concrete placing machine turns back to start the second concrete placing under the action of the displacement sensor and proximity switch, achieving the simultaneous completion of concrete placing and the first vibration;

S4, the RGV trolley transports the poured model to the second vibration station, and uses the set frequency and vibration time to complete the secondary vibration. The RGV trolley then moves the next model to the first vibration station under the control of the central control system of the vacated first vibration station;

S5. Repeat steps S1 to S4 to form a flow operation, which greatly improves the injection efficiency.

Specifically, the vibration time and frequency are determined by experiments: the first vibration frequency is set to 80Hz, 85Hz, 90Hz, and the vibration time is 60s, 70s, 80s, 90s; the second vibration frequency is set to 100Hz, 110Hz, 115Hz, and the vibration time is 70s, 80s, 90s. According to these parameters, the casting is steamed, demolded, and the appearance quality of the product is observed. After three months of experimental analysis and summary, it is concluded that the first vibration is 90Hz, the vibration time is 80s, which just completes the concrete spreading, and the second vibration is 110Hz, the vibration time is 90s, the product appearance is better, there are fewer bubbles, and no over-vibration water lines appear. The whole mold casting time is (5~6)min, and the water flow rhythm is good.

Compared with the existing technology, this solution has significant beneficial effects. First, it saves a workstation and shortens the pouring workstation time, speeds up the flow rhythm, and reduces the pouring time from the original 8 minutes to less than 6 minutes, saving 2 minutes; secondly, it reduces 3 operators and reduces labor intensity; then it achieves precise and continuous material distribution, improves the integrity and continuity of product pouring, improves the appearance quality of the product, and eliminates the waste of concrete. The working degree selection of one-click concrete distribution can match the walking frequency and number of the concrete distributor 3, as well as the frequency selection and vibration time of the double-station variable frequency vibration.

Claims (10)

1. A double-block sleeper double-station pouring system, characterized in that it comprises a concrete transport and material distribution system arranged on a first vibrating station, a first vibrating table (5) arranged below the first vibrating station, and a second vibrating table (6) arranged on the second vibrating station, wherein a guide track is arranged between the first vibrating table (5) and the second vibrating table (6), and a transport trolley is arranged on the track; The concrete transport and distribution system comprises a transverse transport frame (1) and a longitudinal transport frame (2) which are orthogonally installed, wherein the transverse transport frame (1) is erected above the longitudinal transport frame (2); the transverse transport frame (1) is provided with a high hopper (4) which can reciprocate transversely along the transverse transport frame (1), and the longitudinal transport frame (2) is provided with a concrete distributor (3) which can reciprocate longitudinally along the longitudinal transport frame (2), and the discharge port of the high hopper (4) cooperates with the feed port of each concrete distributor (3); the first vibration table (5) is fixed on the ground below the longitudinal transport frame (2), the first vibration table (5) and the second vibration table (6) are used to place the model to be poured, and the first vibration table (5) cooperates with the concrete distributor (3). 2. The double-block sleeper double-station pouring system according to claim 1 is characterized in that the first vibration table (5) and the second vibration table (6) are both provided with two groups of vibration plates with vibrators for placing models, and each of the vibration plates is provided with a proximity switch that cooperates with the automated RGV trolley. 3. The double-block sleeper double-station pouring system according to claim 2 is characterized in that each of the vibration plates is provided with two vibration motors, the vibration frequency of each of the vibration motors is adjustable, and the frequency of each of the vibration motors is between 80 and 120 Hz. 4. The dual-block sleeper dual-station pouring system according to claim 1, characterized in that each of the concrete placing machines (3) is provided with a proximity switch of an induction model. 5. The double-block sleeper double-station pouring system according to claim 1 is characterized in that it also includes a concrete feeding truck for receiving concrete mixed by the mixer, the concrete feeding truck receives the material at the discharge port of the mixing station, and automatically moves along the track, and the concrete feeding truck feeds the high hopper (4). 6. The double-block sleeper double-station pouring system according to claim 5 is characterized in that a material gate is provided at the discharge port of the concrete feeder truck, and a hydraulic cylinder for driving the material gate to open and close is also provided at the discharge port of the concrete feeder truck. 7. The dual-block sleeper dual-station pouring system according to claim 2 is characterized in that the transport trolley is an automated RGV trolley. 8. The double-block sleeper double-station pouring system according to claim 7 is characterized in that a lifting cylinder is provided on the RGV trolley. 9. A double-block sleeper double-station pouring method, characterized in that the double-block sleeper double-station pouring system according to any one of claims 1 to 8 is adopted. 10. A double-block sleeper double-station pouring method according to claim 9, characterized in that it comprises the following steps: S1. Use the automated RGV trolley to transport the model to the fixed vibration table, and place it accurately on the vibration table under the action of the proximity switch; S2. Unload the concrete in the high hopper (4) into the automatic concrete placing machine in advance, and then start the one-button automatic concrete placing program. The automatic concrete placing machine automatically discharges the concrete at the set walking frequency. When the concrete reaches the end of the model and reaches 80% of the height inside the model, it starts to vibrate. S3, the concrete is quickly vibrated and the automatic concrete placing machine turns back to start the second concrete placing under the action of the displacement sensor and proximity switch, achieving the simultaneous completion of concrete placing and the first vibration; S4, the RGV trolley transports the poured model to the second vibration station, and uses the set frequency and vibration time to complete the secondary vibration. The RGV trolley then moves the next model to the first vibration station under the control of the central control system of the vacated first vibration station; S5. Repeat steps S1 to S4 to form a flow operation, which greatly improves the injection efficiency.