CN103128847B - Double-block type sleeper production line and production process thereof - Google Patents
Double-block type sleeper production line and production process thereof Download PDFInfo
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- CN103128847B CN103128847B CN201310054478.8A CN201310054478A CN103128847B CN 103128847 B CN103128847 B CN 103128847B CN 201310054478 A CN201310054478 A CN 201310054478A CN 103128847 B CN103128847 B CN 103128847B
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Abstract
The invention discloses a double-block type sleeper production line and a production process thereof and belongs to the technical field of sleeper processing in high speed railway. The production process includes the following steps: pouring vibration, mould roller bed delivery, pre-kiln-entering mould chain delivery, double-mould simultaneous stacking and kiln entering, pit type maintenance, double-mould automatic jam breaking kiln leaving, post-kiln-leaving mould chain transmission, midair automatic mould turning, automatic demoulding, sleeper automatic transportation, sleeper chain type delivery to stacking area, roller bed delivery, release agent clearing and steel bar truss addition. The production process can reduce production cost, improves processing efficiency and ensures product quality.
Description
Technical field
The invention belongs to sleeper processing technique field in high-speed railway.
Background technology
Along with the fast development of global economy, various countries, to the construction of railway transportation, have particularly carried out extensive, deep research to the construction of infrastructure sleeper.The sleeper that current railway uses is mainly by sleeper and concrete sleeper.Elasticity and the insulating properties of timber are better, influence of temperature change by surrounding medium is little, process and change easy on the line, and there are enough resistances to displacement, but along with the minimizing of the forest reserves and the enhancing of people's environmental consciousness, some country starts to produce steel sleeper and reinforced concrete sleeper, to replace sleeper.
Enter 21 reality, the intercity contact of personnel is frequent, and various countries start to build high-speed railway energetically.Same China makes rapid progress especially on high-speed railway, from Article 1 high-speed railway Beijing-Tianjin inter-city, compatriots just explore the paving pillow of high-speed railway, based on large plate form, until the operation of military wide high ferro, it is found that economy and the convenience of the paving pillow of two block, each Zhong Tie branch office starts two block sleeper production line one after another, and almost no longer adopts large plate form.
At present, produce double-block type concrete sleeper and all adopt unit pipelining production technology, machinery and sleeper mould will move frequently, operate in process of production, and sleeper is produced and adopted unit flowing water method, and steam curing process and channel-type maintenance are gone along with sb. to guard him.In the production process of short mould sleeper, there are the following problems: first, present domestic market 4x1 short mould sleeper production line mostly is tunnel type maintenance, tunnel type maintenance disadvantage is that heating curve is not obvious, Ministry of Railways's requirement can not be met, but change pit maintenance into, enter kiln kiln discharge and be an overhead traveling crane job, efficiency again reduces.The second, maintenance district is overmanning, and about about 6 people, integral production line automation degree is strengthened.Three, factory building takes up an area large, and factory building width is at 21 meters to 24 meters.
Summary of the invention
The technical problem to be solved in the present invention is to provide a kind of double-block type sleeper production line and production technology thereof, this production line can improve sleeper working (machining) efficiency effectively, and the sleeper of production utilizes pit maintenance, meets Ministry of Railways's engine request, and save manpower, easily realize automation.
For solving the problems of the technologies described above, the technical solution used in the present invention is: a kind of double-block type sleeper production line, it is characterized in that involving vibrations platform, the material distributing machine that can horizontally slip along slide rail is provided with above described shake table, the left side of shake table, rise and fall roller is provided with between slide rail, the first mould chain-linked conveyer connected vertically with slide rail is provided with in the side of rise and fall roller, the right side of shake table is provided with rollgang, tilting bed is provided with above the middle part of rollgang, rollgang right end is provided with the second mould chain-linked conveyer, second mould chain-linked conveyer is provided with aerial automatic die-turning machine, first mould chain-linked conveyer is connected by automatic stacking machine with the free end of the second mould chain-linked conveyer, sleeper output device is provided with on the right side of rollgang.
Do to supplement further to said structure, described sleeper output device comprises automatic demoulding platform, sleeper chain-linked conveyer, sleeper travelling bogie and sleeper automatic stacking machine, sleeper travelling bogie is placed between automatic demoulding platform and sleeper chain-linked conveyer, and the end of sleeper chain-linked conveyer is provided with sleeper automatic stacking machine.
Do to supplement further to said structure, described shake table is plural arranged in series.In the present invention, by two vibrations station of connecting, realize material distributing machine one direction cloth, eliminate the action of transverse shifting cloth, improve cloth efficiency and cloth quality.
In the present invention, the transmission of mould is all completed by chain-linked conveyer, such as the mould of building by chain conveying to maintenance district, advantage is that mould can realize two and is arranged side by side in maintenance district, possesses Mould Code stack machine and can to sling two moulds simultaneously.
A production technology for double-block type sleeper production line, is characterized in that described production technology is as follows:
Step 1 builds vibration: by rollgang, mould is transported near shake table, and the material distributing machine of being walked by left and right carries out one direction to mould all has cloth, then passes through the double shake table of series connection to the concrete compaction in mold cavity;
Step 2 mould is carried: be sent on rise and fall roller by the mould of building, rise and fall roller mold drops on the first mould chain-linked conveyer, lateral transfer mould, adjacent two moulds side by side, makes it to possess the condition that automatic stacking machine can lift two moulds simultaneously;
Step 3 maintenance: on maintenance district chain-linked conveyer after two moulds placed side by side, automatic stacking machine sling simultaneously send into curing kilns carry out ground pit type maintenance, after maintenance completes, mould good for maintenance in melt pit is lifted two moulds by automatic stacking machine simultaneously, is placed on the second mould chain-linked conveyer.
Step 4 turns over mould, the demoulding: the mould that maintenance is good is sent to upset demoulding district, mould is captured from the second chain-linked conveyer, carry out 180 degree of upsets, automatic die-turning machine body 90-degree rotation simultaneously, then be placed on automatic demoulding platform, stripping station air bag jack-up mould, rapid venting, mould falls rapidly by gravity, drops to the moment of the back-up block in stripping station, vibration is produced to mould, after the demoulding, then capture mould from stripping station, carry out negative 180 degree of revolutions, then be placed on mould rollgang, enter step 7; Sleeper after the demoulding is placed on automatic demoulding platform, enters step 5;
Step 5 sleeper transports: after the demoulding, sleeper travelling bogie is transported to sleeper chain-linked conveyer sleeper jack-up, and sleeper chain-linked conveyer is transported to sleeper automatic stacking machine place sleeper;
Step 6 sleeper piling: sleeper automatic stacking machine becomes bag sleeper automatic stacking, 4 rows 5 layers totally 12 one bag, are finally gone out by forklift transport;
Step 7 is cleared up, coating release agent: after step 4 completes, and adopts inclination roller-way by the mold tilt after the demoulding, carries out the cleaning of mould inner concrete residue, ixoderm, then coating release agent;
Step 8 adds steel bar girder in the mould cleared up, and returns step 1 and carries out next round circulation technology.
The beneficial effect adopting technique scheme to produce is: in this production technology, the change of matter has been carried out in maintenance region, apply chain-linked conveyer and automatic stacking machine three equipment, especially the application of automatic stacking machine, lift two moulds, the beat of equipment is fast one times at every turn simultaneously, thus change ground pit type maintenance into, compared with original tunnel type maintenance, not only do not reduce production line efficiency, and after maintenance, sleeper quality meets national standard completely; In the present invention, device therefor is Automatic Control, and employment is few, save labour, run beat according to design in 3.5-4 minutes, every day 2 classes produces for 24 hours, namely workman produced evening production line and rested and carry out maintenance work daytime, and adopted the production model of two vibration station, produced about 1500 daily.This technique is open, can increase curing kilns quantity and mould, roller-way quantity increases, therefore can increase the sleeper daily output accordingly.
Accompanying drawing explanation
Below in conjunction with the drawings and specific embodiments, the present invention is further detailed explanation.
Fig. 1 is production line of the present invention;
Fig. 2 is process chart of the present invention;
1, material distributing machine, 2, shake table, 3, rollgang; 4, the first mould chain-linked conveyer; 5, automatic stacking machine, 6, aerial automatic die-turning machine, 7, tilting bed; 8, automatic demoulding platform; 9, sleeper chain-linked conveyer, 10, rise and fall roller, 11, sleeper automatic stacking machine; 12, sleeper travelling bogie, the 13, second mould chain-linked conveyer.
Detailed description of the invention
The concrete a kind of double-block type sleeper production line of the present invention and technique thereof, be mainly used in the production of 4 × 1 short mould sleepers in high-speed railway.
Concrete product line group becomes: a kind of double-block type sleeper production line, involving vibrations platform 2, the material distributing machine 1 that can horizontally slip along slide rail is provided with above described shake table 2, the left side of shake table 2, rise and fall roller 10 is provided with between slide rail, the first mould chain-linked conveyer 4 connected vertically with slide rail is provided with in the side of rise and fall roller 10, the right side of shake table 2 is provided with rollgang 3, tilting bed 7 above the middle part of rollgang 3, rollgang 3 right end is provided with the second mould chain-linked conveyer 13, second mould chain-linked conveyer 13 is provided with aerial automatic die-turning machine 6, first mould chain-linked conveyer 4 is connected by automatic stacking machine 5 with the free end of the second mould chain-linked conveyer 13, sleeper output device is provided with on the right side of rollgang 3.Sleeper output device comprises automatic demoulding platform 8, sleeper chain-linked conveyer 9, sleeper travelling bogie 12 and sleeper automatic stacking machine 11, sleeper travelling bogie 12 is placed between automatic demoulding platform 8 and sleeper chain-linked conveyer 9, and the end of sleeper chain-linked conveyer 9 is provided with sleeper automatic stacking machine 11.Shake table 2 is plural arranged in series.
The production technology of above-mentioned double-block type sleeper production line, is characterized in that described production technology is as follows: build vibration → mould roller-way carry → enter kiln front mold chain delivery → bimodulus simultaneously automatic stacking enter kiln → ground pit type maintenance → bimodulus automatic de-stacking kiln discharge → kiln discharge rear mold chain delivery → aerial automatic turning mould → automatic demoulding → sleeper automatic transportation → sleeper chain conveying and carry → clear up coating release agent etc. → add steel bar girder to piling district → roller-way.
By double-block type sleeper manufacturing technique requirent, the equipment that sleeper production line comprises has: mould, rollgang, concrete distributing equipment, shake table, ground pit type curing system, mould chain-linked conveyer, mould automatic stacking machine, aerial automatic tipping arrangement, demoulding equipment, model cleaning tipping table, sleeper chain conveyor, sleeper automatic stacking machine etc.Mould adopts 4 × 1 short modular forms, and namely can fill 4 sleepers in a mould, appearance and size is that the wide 1600* of long 2800* is high by 330, and mould both sides arrange four cylindrical leads for equipment hoisting; Maintenance has automatic temperature control system to control curing temperature.
First, pouring concrete with vibrate district mainly concrete dispenser by the mould of concrete supply to 4 × 1.Concrete adopts gradation feed and is vibrated by dither simultaneously.Smash and shake from autofeed, until reach optimal concrete density, when building, carry out the inspection of concrete height.Also need in process of vibrating manually to carry out troweling process to concrete surface, after concrete vibrating completes, utilize steel brush to clear up residual concrete.In the process of vibrating, no skew when checking the position of truss bars, if there is skew, is vibrating after correction.
Cloth vibrational system in the present invention is made up of material distributing machine, two vibration station and rollgang, and major function has been concrete cloth, vibration moulding; Material distributing machine function is casting concrete material upper walking automatically and energy cloth is driven a vehicle in trend 4x1 mould; Shake table function has been the exhaust, closely knit and shaping of concrete materials; Rollgang function is transported to next station by being loaded with through the mould of vibration moulding sleeper.
Wherein, material-feeding mechanism uses material distributing machine to vertically move, and realizes the movement arbitrarily in job area of cloth function, accurately completes front and back double concreting; Adopt west gate PLC technology and SEW variable-frequency driving technique, equipment walking position is accurate, and device security is perfect.What is more important converter technique well coordinates movable motor and cloth motor speed, for accurate cloth provides good guarantee; Adopt hydraulic pressure and pneumatics, pneumatic control feed bin door compensate for hydraulic operation shortcoming slowly, realizes accurate cloth simultaneously; Shake table is the core position of whole production line, directly affects the final mass of sleeper, and parts are equipped with, control to have employed the top configuration in the world for this reason; Control system is Siemens S7-300 Programmable Logic Controller, and drive system is SEW frequency conversion drive, and vibration parameters is adjustable; Vibrating motor is selected from Italy, and air bag is selected from Germany, and floated vibrational structure is selected from German Hai Si, and optimized combination fundamentally ensure that sleeper manufacturing technique requirent.
In cloth process, make the material at each position even, appropriate by material distributing machine to concrete perfusion in model, too dry or too rare compound must not come into operation as far as possible.Blanking at least divides two-layer, if find, foreign material will take out in time, and do not have above the pillow of model two ends concrete, carries out closely knit with automated manner.
Ground pit type maintenance completes in steam-cured passage, and mainly accelerate to make concrete reach intensity by steam curing, maintenance passage divides heating zone, flat-temperature zone and cooling area; Curing system is made up of curing pool, mould automatic stacking machine, mould chain-linked conveyer; Adopt steam curing in curing pool, be furnished with monitoring system, can automatically control maintenance intra passage temperature and humidity; Because the special construction of 4x1 mould designs, when sleeper passes through the maintenance passage of variations in temperature in official hour, can ensure that 12 stacked every layer, the moulds put can both fully contact with steam, optimize maintenance effect, to guarantee to meet the requirements of intensity;
Turning over moulding/demoulding system mainly adopts aerial automatic die-turning machine, automatic demoulding equipment to be deviate from from model by the sleeper reaching design strength, and then sleeper is transported to detection zone or piling district, model is transported to clearing zone and carries out next one circulation;
Sleeper palletizing system forms by transporting pillow dolly, sleeper chain-linked conveyer, sleeper automatic stacking machine etc.Major function is: the sleeper that the demoulding is good moves on sleeper chain-linked conveyer by transporting pillow dolly, and operator realizes resting the head on appearance quality detection, fastener installment work on chain-linked conveyer.Sleeper is finally transported to chain-linked conveyer end, arranges sleeper automatic stacking machine here, and sleeper is piled up 5 layers by sleeper automatic stacking machine, 4 every layer, and after final piling, a buttress is 20, is inserted away be transported to sleeper stacking field by fork truck.
Upset dismoulding system and sleeper palletizing system system adopt PLC technology and SEW variable-frequency driving technique, and hydraulic synchronization drives, the mode such as pneumatic realizes respective action.
Mould retrieval system has 9 groups of rollgangs, wherein there are two groups of rollgangs to have tilt functions, have been mainly used in mold cleaning, spraying releasing agent operation, rear several groups of rollgangs carry out the installation such as reinforcing bar and insulating sleeve, compact layout and structure, utilization rate of equipment and installations is high.
Cleaning, coating release agent process be complete at mold clean station, it mainly adopts inclination roller-way by the mold tilt after the demoulding 80 °, adopt specific purpose tool to carry out mold cleaning, residual for the concrete in the model tiny fragments of stone, coal, etc., ixoderm etc. are cleaned out, mould is tested.Detailed process is: when the mold movement after the demoulding is to mold clean inclination roller-way, fixed mould on inclination roller-way, then tilt roller-way (angle of inclination is 80 °), cleaning with high pressure air rifle of template, the smoothness not damaging template interior surface is by high pressure air rifle cleaning template advantage, and it is quick, laborsaving.Need check whether template is damaged, whether interior surface is smooth when cleaning template, have no concave-convex phenomenon, with or without comparatively dark or affect the scratch of sleeper surface flatness, although the probability that this phenomenon generally occurs is very little, should be noted that.If coating release agent station owner brushing releasing agent, so that the good demoulding.During coating release agent notably, tubing is pressed after first coating release agent.Forbid releasing agent and casing-contact, plastics to want appropriate, must not in template, have collection to stay, having smeared rear inspection template corner has the releasing agent not collecting on a small quantity and stay, as useful rag is cleaned.Template inner pattern releasing agent applicable will be smeared complete, and this has a significant effect to demoulding efficiency and sleeper surface flatness;
Finally, in steel bar girder installation station, two steel bar girders are mainly installed, and accurately locate; Then the bent-up bar placed in groove in-orbit and reinforced mesh are accurately located.Accurate location mainly relies on the truss bars support slot in template.When truss bars fixes, bent-up bar is carried out colligation with steel bar girder, when bent-up bar and steel bar girder colligation, adopts special insulating sleeve to insulate.
4 × 1 short mould unit line production system are adopted in this production technology.Run beat according to design in 3.5-4 minutes, 24 hours every days 2 classes produce, and namely workman produced evening production line and rested and carry out maintenance work daytime, and adopted the production model of two vibration station, produced about 1500 daily.If curing kilns quantity and mould, roller-way quantity increases, and can increase the sleeper daily output accordingly.
Claims (1)
1. a double-block type sleeper production line, it is characterized in that comprising plural arranged in series shake table (2), described shake table (2) top is provided with the material distributing machine (1) that can horizontally slip along slide rail, the left side of shake table (2), rise and fall roller (10) is provided with between slide rail, the first mould chain-linked conveyer (4) connected vertically with slide rail is provided with in the side of rise and fall roller (10), the right side of shake table (2) is provided with rollgang (3), tilting bed (7) is provided with above the middle part of rollgang (3), rollgang (3) right end is provided with the second mould chain-linked conveyer (13), second mould chain-linked conveyer (13) is provided with aerial automatic die-turning machine (6), first mould chain-linked conveyer (4) is connected by automatic stacking machine (5) with the free end of the second mould chain-linked conveyer (13), sleeper output device is provided with on rollgang (3) right side, described sleeper output device comprises automatic demoulding platform (8), sleeper chain-linked conveyer (9), sleeper travelling bogie (12) and sleeper automatic stacking machine (11), sleeper travelling bogie (12) is placed between automatic demoulding platform (8) and sleeper chain-linked conveyer (9), and the end of sleeper chain-linked conveyer (9) is provided with sleeper automatic stacking machine (11).
2.the production technology of a kind of double-block type sleeper production line as described in claim 1, is characterized in that described production technology is as follows:
Step 1 builds vibration: by rollgang (3), mould is transported near shake table (2), and the material distributing machine (1) of being walked by left and right carries out one direction to mould all has cloth, then passes through the double shake table of series connection to the concrete compaction in mold cavity;
Step 2 mould is carried: be sent to by the mould of building on rise and fall roller (10), rise and fall roller (10) mold drops on the first mould chain-linked conveyer (4), lateral transfer mould, adjacent two moulds side by side, make it to possess the condition that automatic stacking machine (5) can lift two moulds simultaneously;
Step 3 maintenance: on maintenance district chain-linked conveyer after two moulds placed side by side, automatic stacking machine (5) sling simultaneously send into curing kilns carry out ground pit type maintenance, after maintenance completes, mould good for maintenance in melt pit is lifted two moulds by automatic stacking machine (5) simultaneously, is placed on the second mould chain-linked conveyer (13);
Step 4 turns over mould, the demoulding: the mould that maintenance is good is sent to upset demoulding district, mould is captured from the second mould chain-linked conveyer (13), carry out 180 degree of upsets, automatic die-turning machine body revolves and turn 90 degrees simultaneously, then be placed on automatic demoulding platform (8), stripping station air bag jack-up mould, rapid venting, mould falls rapidly by gravity, drops to the moment of the back-up block in stripping station, vibration is produced to mould, after the demoulding, then capture mould from stripping station, carry out negative 180 degree of revolutions, then be placed on mould rollgang, enter step 7; Sleeper after the demoulding is placed on automatic demoulding platform (8), enters step 5;
Step 5 sleeper transports: after the demoulding, sleeper travelling bogie (12) is transported to sleeper chain-linked conveyer (9) sleeper jack-up, and sleeper chain-linked conveyer (9) is transported to sleeper automatic stacking machine place sleeper;
Step 6 sleeper piling: sleeper automatic stacking machine (11) becomes bag sleeper automatic stacking, 4 rows 5 layers totally 12 one bag, are finally gone out by forklift transport;
Step 7 is cleared up, coating release agent: after step 4 completes, and adopts inclination roller-way by the mold tilt after the demoulding, carries out the cleaning of mould inner concrete residue, ixoderm, then coating release agent;
Step 8 adds steel bar girder in the mould cleared up, and returns step 1 and carries out next round circulation technology.
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| CN201310054478.8A CN103128847B (en) | 2013-02-20 | 2013-02-20 | Double-block type sleeper production line and production process thereof |
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| CN109834814B (en) * | 2019-04-04 | 2021-10-08 | 廊坊海斯建材机械有限公司 | Precast concrete production line |
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