CN107225671B - Flexible flow production line for producing ballastless track plate by pre-tensioning method - Google Patents
Flexible flow production line for producing ballastless track plate by pre-tensioning method Download PDFInfo
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- CN107225671B CN107225671B CN201710593953.7A CN201710593953A CN107225671B CN 107225671 B CN107225671 B CN 107225671B CN 201710593953 A CN201710593953 A CN 201710593953A CN 107225671 B CN107225671 B CN 107225671B
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- 239000003795 chemical substances by application Substances 0.000 claims description 43
- 238000012423 maintenance Methods 0.000 claims description 38
- 238000009413 insulation Methods 0.000 claims description 36
- 238000009434 installation Methods 0.000 claims description 16
- 238000005266 casting Methods 0.000 claims description 14
- 238000007788 roughening Methods 0.000 claims description 13
- 238000004140 cleaning Methods 0.000 claims description 11
- 239000006082 mold release agent Substances 0.000 claims description 11
- 238000007789 sealing Methods 0.000 claims description 10
- 230000007704 transition Effects 0.000 claims description 10
- 229910001294 Reinforcing steel Inorganic materials 0.000 claims description 4
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
- B28B15/007—Plant with two or more identical shaping or moulding devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
- B28B1/087—Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
- B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
- B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
- B28B23/043—Wire anchoring or tensioning means for the reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B7/00—Moulds; Cores; Mandrels
- B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
- B28B7/388—Treating surfaces of moulds, cores, or mandrels to prevent sticking with liquid material, e.g. lubricating
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Machines For Laying And Maintaining Railways (AREA)
- General Factory Administration (AREA)
Abstract
According to the flexible flow production line for producing the ballastless track plate by the pre-tensioning method, the auxiliary tracks such as the outer track, the inner track and the cross track are added on the basis of the existing annular production track, the rapid strain capacity in production is optimized by adopting double-path and double-station design improvement, and equipment can be used. The track plate production line is compatible with the collinear operation of ballastless track plate moulds of various specifications to produce track plates, and can realize the collinear production of the moulds of two specifications simultaneously, so that the equipment utilization rate is improved, the equipment investment is reduced, the automatic equipment is intelligently controlled by a central control room, the operation capacity of the production line can be adjusted by adopting flexible process programs, the flexibility is higher, the design of double stations and the steam curing module (steam curing room) which can be increased and decreased can flexibly adjust the yield of the track plates to be matched with the engineering progress.
Description
Technical Field
The invention relates to a track slab production line for a high-speed railway, in particular to a flexible flow production line for producing ballastless track slabs by a pre-tensioning method.
Background
The ballastless track slab used in the high-speed railway in China is influenced by factors such as line trend, terrain and the like, and the same slab type also has different design specifications, for example, the CRTSIII type ballastless track slab which is independently and vigorously popularized in China has the design specifications of P5600, P4856, P4925 and P3710, wherein the P5600 specification is the slab type with the most application amount, and the yield (application amount) of other specifications is relatively less but indispensable.
At present, the production mode of the ballastless track slab produced by the pre-tensioning method is gradually changed from the production mode of a pit matrix pedestal to the production mode of a production line along with the technical progress, but because the specifications of the ballastless track slab are not uniform, a production line cannot be built for each specification, so that the production line is necessarily required to have certain flexibility and be compatible with the equipment conditions and the process technology method of the ballastless track slabs of various specifications.
The problems of the ballastless track slab produced by the flow line are as follows: because the production line is a production mode system with efficient operation, technical faults or accidents such as key equipment or processes must exist in the using process, if a problem (or technical adjustment) occurs in a certain key link of the production line, the operation of the whole production line can be influenced, the production rhythm of the process can be influenced, the yield in unit time can be reduced, and the delay and the stagnation of high-speed railway engineering projects can be indirectly caused.
In the process of producing the ballastless track slab by the assembly line, the manufacturing flows of all process nodes are different, the consumed time is different, and more equipment waiting conditions are inevitably generated, so that the problem of time waste is caused; and because the yield of the ballastless track plate is related to the construction progress and the demand of the high-speed rail engineering, the production progress amount is required to be controlled according to the actual demand and the demand time, so that the condition that the yield is insufficient or the inventory is too large and the occupied land is wasted is avoided.
Another disadvantage of the prior art is that it is difficult to adapt to different terrain restrictions by using a single circular track, so the site selection of the factory must search for a terrain with a large area, often occupies a large amount of farmland, and is very difficult to select the site particularly in hilly and angular regions.
In summary, a flexible flow production line for producing ballastless track slabs by a pre-tensioning method is needed in the current production link, the equipment compatibility problem and the process compatibility problem caused by mold change are solved, the problem of production stagnation caused by reasons is avoided, and the problem of how to economically run the production line caused by yield change is adapted.
Disclosure of Invention
Aiming at the problems, the invention provides a flexible flow production line for producing ballastless track plates by a pre-tensioning method. The problem of prior art's single annular flow production line can not produce different specification track boards simultaneously and must shut down the line when overhauing and breaking down is solved. Meanwhile, the invention also solves the problem of topographic limitation of the application environment of the current production line and can set the position of each station according to the field condition. The invention also provides a flexible flow production line operation method for producing the ballastless track plate by the pre-tensioning method.
A flexible flow production line for producing ballastless track plates by a pre-tensioning method comprises a plurality of operation stations arranged according to a process sequence, a track arranged along the operation stations and at least one operation trolley running on the track for transferring track plates and/or track plate molds, wherein the track is connected end to form an annular track.
The flexible flow production line for producing the ballastless track plate by the pre-tensioning method is characterized in that the auxiliary track is arranged on the inner side and/or the outer side of the annular track and/or is arranged in a manner of crossing the annular track.
The flexible flow production line for producing the ballastless track plate by the pre-tensioning method is characterized in that the track is a tangible solid track or an intangible ground walking route for the running trolley to walk, and each production station is arranged along the walking track/route according to the process sequence.
The flexible flow production line for producing the ballastless track plate by the pre-tensioning method is characterized in that a mould cleaning station, a mould detection station, a first embedded part installing and mould releasing agent coating station, a first steel cage locating and pre-tightening station, a first tensioning station, an insulation detection station, a first vibration casting station, a second vibration casting station, a roughening station, a steam curing station, a first releasing station and mould releasing station, a central control room and an operation signal detection device connected with the central control room and installed on each station are sequentially arranged on the circular track according to the process sequence.
The flexible flow production line for producing the ballastless track plate by the pre-tensioning method is characterized by being provided with a first outer side track, wherein a second embedded part installation and release agent coating station, a second steel cage in-position and pre-tensioning station and a second tensioning station are sequentially arranged on the first outer side track, the second embedded part installation and release agent coating station, the second steel cage in-position and pre-tensioning station and the second tensioning station are arranged in parallel with the first embedded part installation and release agent coating station, and the first steel cage in-position and pre-tensioning station and the first tensioning station are arranged in parallel.
The flexible flow production line for producing the ballastless track plate by the pre-tensioning method is characterized by being provided with a first inner side track, a second inner side track and a third inner side track, wherein the first inner side track is provided with an unqualified mould maintenance station adjacent to a mould detection station, the first inner side track is also provided with an unqualified insulation detection maintenance station adjacent to an insulation detection station, the second inner side track is provided with a second releasing station, and the third inner side track is connected with an equipment maintenance area.
The flexible flow production line for producing the ballastless track plate by the pre-tensioning method is characterized in that a transition station is arranged between the steam curing station and the first releasing station, and an equipment maintenance interval is reserved between the transition station and the first releasing station.
The flexible flow production line for producing the ballastless track plate by the pre-tensioning method is characterized by being provided with a first cross track and a second cross track, wherein the second cross track is provided with an anchor sealing station and a plate turning station, and the second cross track is connected with a track at the position of a demolding station.
A flexible flow production line operation method for producing ballastless track plates by adopting a pre-tensioning method is characterized by comprising the following steps:
the first step is as follows: the running trolley carries the empty mold to a mold cleaning station through the annular rail or the auxiliary rail, and the mold is cleaned to meet the requirements of the process specification;
the second step is that: the cleaned mould is carried to a mould detection station by an operation trolley, standardized detection is carried out by mould detection equipment, and the qualified mould enters a first mounting embedded part and mould release agent coating station or a second mounting embedded part and mould release agent coating station arranged on a second outer side rail; the unqualified person enters an unqualified die maintenance station on the first inner side track to be detected or maintained, and returns to a die detection station for secondary detection after maintenance;
the third step: entering a qualified mold of a first installation embedded part and mold release agent coating station and/or a second installation embedded part and mold release agent coating station to coat a mold release agent and install the embedded part;
the fourth step: a mould which is coated with a release agent and provided with the embedded part on a first embedded part mounting and release agent coating station is delivered to a first steel cage positioning and pre-tightening station on an annular track through a running trolley, and the mould can be directly conveyed into a second steel cage positioning and pre-tightening station through a second outer side track or a first cross track when the first steel cage positioning and pre-tightening station is in an overhauling or fault state; a mold which is coated with the release agent and is arranged on a second embedded part mounting and release agent coating station is transported to a second steel cage positioning and pre-tightening station on a first outer side rail by a running trolley, and when the second steel cage positioning and pre-tightening station is in an overhauling or fault state, a rail plate which is rotated out by the second embedded part mounting and release agent coating station can be directly conveyed into the first steel cage positioning and pre-tightening station by an auxiliary rail;
the fifth step: entering a track plate mould of a first steel cage entering position and a pre-tightening station and/or a second steel cage entering position and a pre-tightening station to sequentially carry out steel cage entering position, pre-tightening and copper bar installation;
and a sixth step: the die completing the operation of the first steel cage in-position and the pre-tightening station is carried to a first tensioning station by an operation trolley for tensioning, and when the first tensioning station is in a maintenance or fault state, the die can enter a second tensioning station through an auxiliary rail; the die completing the operation of the second steel cage in position and the pre-tightening station is carried to a second tensioning station by the running trolley for tensioning operation, and the second tensioning station can be directly transferred to the first tensioning station when in a maintenance or fault state;
the seventh step: the die conveyed out of the first tensioning station and/or the second tensioning station enters an insulation detection station on the annular rail to perform insulation detection on the steel bar, and the steel bar is conveyed to a first vibration casting station or a second vibration casting station on the annular rail by a running trolley after the detection is qualified; the die with unqualified insulation detection enters an unqualified insulation detection maintenance station for adjustment, and then returns to the insulation detection station for secondary detection;
eighth step; the mould entering the vibration pouring station performs material distribution and pouring according to a set program and performs intermittent vibration to complete the track slab forming operation;
the ninth step: the formed track plate and track plate mould is transported to a roughening station by an operation trolley, and roughening operation is carried out on the exposed surface of the track plate in the track plate mould by roughening equipment;
the tenth step; the track slab mold and the track slab which are finished with the roughening operation are transported to a steam curing room by an operation trolley to carry out steam curing operation;
the eleventh step: the rail plate and the rail plate mold after the steam curing operation is finished are sent to a first tension placing station or a second tension placing station to carry out synchronous tension placing operation on the tension steel bars in the rail plate;
the twelfth step: conveying the track slab and the track slab die after synchronously releasing and tensioning the reinforcing steel bars to a demolding station, demolding the track slab by demolding equipment, and collecting and transferring die steel bar accessories by steel bar transferring equipment;
a tenth step; the demoulded track slab mold enters a mold cleaning station and enters the next cycle operation, and the demoulded track slab is transported to an anchor sealing station by an operation trolley to carry out anchor sealing operation;
the fourteenth step is that: and (4) carrying the rail plate after the anchor is sealed to a turnover device by a running trolley, turning the upper surface of the turnover device for 180 degrees in a large scale, carrying out three-dimensional size detection on the surface of the rail plate, and warehousing qualified products.
The operation method of the flexible flow production line for producing the ballastless track plate by adopting the pre-tensioning method is characterized by comprising the following steps of: the equipment corresponding to the first installation embedded part and release agent coating station and the second installation embedded part and release agent coating station, the first steel cage entering and pre-tightening station and the second steel cage entering and pre-tightening station, the first tensioning station and the second tensioning station, and the first releasing station and the second releasing station is provided with an adjusting station matched with moulds of different specifications and preset process conditions so as to adapt to the random adjustment of moulds of multiple specifications.
The type of the die corresponds to the specification type of the ballastless track plate in the production process. The production line can meet the requirement that two kinds of moulds are mixed and woven to carry out circulation production, and can realize that any one of the two kinds of moulds is replaced by the mould mixed and woven production of the third specification on line under the condition that the production line is not stopped. In addition, when main equipment in a production line needs to be overhauled or breaks down and needs to be maintained, the double-station arrangement can ensure that production is continuously carried out and the supply of the track slab cannot be stopped.
The die detection equipment/unqualified die overhaul area and the insulation detection equipment/unqualified insulation detection overhaul station are provided with conveying rails for detecting or reworking due to the fact that detection is not passed, and can run or stop in a reciprocating mode according to process design.
When the insulation detection is unqualified, the steel wire cage cannot pass the maintenance, the steel wire cage needs to be detached from the die and reworked, and the corresponding working die can be sequentially operated by an unqualified insulation detection maintenance station, an unqualified die maintenance area, die detection equipment, embedded part demolding agent coating equipment, steel bar pre-tightening positioning equipment, tensioning equipment and insulation detection equipment.
The device for mounting the embedded part and coating the release agent, the device for pre-tightening and positioning the reinforcing steel bar, the tensioning device and the releasing device are all provided with adjusting positions and preset process conditions corresponding to dies with different specifications. When a certain mould needs to be inserted for production, one of the two paths of devices in the two-path parallel operation can be automatically/manually adjusted to preset process conditions and adjustment positions, and the other path of devices continues to run in a non-stop flow-turning mode according to the production process.
The steel bar enters the position equipment, the steel bar pretension positioning equipment and the mould steel bar transfer equipment room and still are provided with a track for the operation of a small-sized hoisting device, so that the hoisting of a steel bar cage into the position mould and the transportation of the mould steel bar can be realized.
The central control room has the functions of sensing the working (or stopping) state of equipment at each station, the process running time, the position of the running trolley, and the positions of a mold and a track plate finished product.
The invention has the advantages and positive effects that: the double-path double-station design is improved, the rapid strain capacity in production is optimized, and the equipment can be used. The track plate production line is compatible with the collinear operation of ballastless track plate moulds of various specifications to produce track plates, and can realize the collinear production of the moulds of two specifications simultaneously, so that the equipment utilization rate is improved, the equipment investment is reduced, the automatic equipment is intelligently controlled by a central control room, the operation capacity of the production line can be adjusted by adopting flexible process programs, the flexibility is higher, the design of double stations and the steam curing module (steam curing room) which can be increased and decreased can flexibly adjust the yield of the track plates to be matched with the engineering progress.
Drawings
FIG. 1 is a schematic diagram of a track arrangement of a flexible flow line for producing ballastless track slabs;
FIG. 2 is a schematic diagram of a rectangular track arrangement of a flexible flow production line for producing ballastless track slabs;
fig. 3 is a schematic view of a flexible flow production line for producing ballastless track slabs.
In the figure, 1-mold cleaning station; 2-a mould detection station; 3-unqualified die maintenance station; 4, mounting an embedded part and a release agent coating station; 5, mounting an embedded part and a release agent coating station; 6-a process adjusting station; 7-positioning and pre-tightening a first steel cage; 8-positioning and pre-tightening a second steel cage; 9-steel cage positioning equipment; 10-a second tensioning station; 11-a first drawing station; 12-an insulation detection station; 13-unqualified insulation detection maintenance station; 14-a first vibratory casting station; 15-a second vibratory casting station; 16-napping station; 17-steam curing room; 18-a transition station; 19-a first release station; 20-a second relaxation station; 21-demolding station; 22-mould bar transfer equipment; 23-anchor sealing station; 24-a turning station; 25-a central control room; 26-the transit interval; 101-an annular track; 201-a first outboard track; 202-a second outboard track; 301-a first inner rail; 302-a second inboard track; 303-a third inner rail; 104-a first cross track; 105-a second cross track; 401-traffic track.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be further described below with reference to the drawings in the embodiments of the present application.
In the flexible flow production line for producing ballastless track slabs by the pre-tensioning method, shown in fig. 1-2, each operation station is sequentially arranged according to the track slab production process along the track of the running trolley for bearing and transferring track slabs and/or track slab molds, and comprises an annular track 101 which is connected end to end, indicated by hollow white double lines in the figure, and is connected with the annular track and provided with an outer track (201, 202), an inner track (301, 302, 303) and a cross track (104, 105).
As shown in fig. 3, a circular track 101 of the invention is provided with a mold cleaning station 1, a mold detection station 2, a first embedded part and mold release agent coating station 4, a first steel cage positioning and pre-tightening station 7, a first tensioning station 11, an insulation detection station 12, a first vibration casting station 14, a second vibration casting station 15, a roughening station 16, a steam curing room 17, a transition station 18, a first releasing station 19 and a demolding station 21. The annular track can be arranged according to the terrain condition, can be rectangular, circular or irregular, and the like, the auxiliary track connected with the annular track can be flexibly arranged according to the terrain condition, the arrangement of the inner track, the outer track or the crossed track is not limited in the figure, and one or more auxiliary tracks or only one or two of three auxiliary tracks can be arranged.
Corresponding operation equipment is installed on each station, the track is positioned at the lower part of the equipment, and the running trolley can pass through the lower part of the equipment when the equipment works. If the running trolley is matched with the precision industrial robot and controlled by the central console, the running trolley directly walks or stops on the ground along a set route, and each station is arranged along the set route of the running trolley according to the process requirements.
The track of the invention comprises a tangible track such as a parallel metal material track fixed on the ground, and a running trolley matched with the tangible track is provided with a metal walking wheel. Or an invisible track, namely belonging to a set path for the running trolley to run, wherein each station is arranged along the central line of the running path, the running trolley is provided with rubber tires or other rollers, universal wheels and the like, the running trolley is provided with a precise control system, such as an industrial robot, each station is provided with a corresponding sensor, and the operation is controlled by a central control room during the running. In addition, devices such as a guide groove, a guide wire and the like can be arranged on the ground to be convenient to control.
A second mounting embedded part and release agent coating station 5, a second steel cage positioning and pre-tightening station 8 and a second tensioning station 10 are arranged on the first outer side rail 201, wherein the second mounting embedded part and release agent coating station 5 is arranged at the crossing position of the first outer side rail 201 and the second outer side rail 202, and a process adjusting station 6 is further arranged at the end point of the second outer side rail and used for process redundancy arrangement and the like in preparation for waiting for the second type of mold, stopping of a running trolley and a production process.
The first cross rail 104 is respectively crossed with the first inner side rail 301, the annular rail and the first outer side rail 201, and an unqualified die maintenance station 3, an unqualified insulation detection maintenance station 13, a first steel cage in-position and pre-tightening station 7 and a second steel cage in-position and pre-tightening station 8 are respectively arranged on the cross points. The two ends of the crossed track are respectively provided with a mould steel bar transfer device 22 and a steel cage in-place preparation station 9, a travelling crane track 401 for the operation of a small travelling crane device is arranged on the first crossed track 104, and the hoisting of the steel cage in-place mould and the transportation of the mould steel bars can be realized.
And an anchor sealing station 23 and a turning station 24 are sequentially arranged on the second cross rail 105, and the rail plate is put in storage for standby after being detected to be qualified at the turning station. The demoulding station 21 is arranged at the intersection of the second cross track and the circular track, the inner end of the second cross station is connected with the first cross track, and the mould steel bar transferring device 22 is arranged at the intersection.
The two ends of the first inner side rail 301 are respectively connected with the annular rail, a mold detection station 2 and an insulation detection station 12 are respectively arranged at the intersection, and an unqualified mold maintenance station 3 and an unqualified insulation detection maintenance station 13 adjacent to the insulation detection station are arranged on the first inner side rail and adjacent to the mold detection station.
The second inner side rail 302 is also connected at both ends thereof to the endless rail, respectively, and is provided with a second expanding station 20, and a third inner side rail 303 is connected to an equipment maintenance station (maintenance area).
The flexible flow production line is provided with a central control room and is controlled to operate by adopting special programming software, and the central control room is provided with a central processing PLC module and has a specific process program suitable for the flexibility of the production line; each station device and the operation trolley are provided with a sensor and a wireless data acquisition module, and the track plate is internally embedded with a radio frequency chip and is provided with a radio frequency chip receiving module. Therefore, the monitoring and control of the production line by the central control room are realized.
The central control chamber is arranged on the inner side or the outer side of the annular track. Each station is provided with a plurality of relevant devices such as an identification sensor, a displacement sensor and the like and is connected with the central control room through wires or wireless connection. Various sensors capable of identifying and ensuring accurate operation are also arranged on each running trolley and connected with the central control room.
The assembly line is provided with equipment matched with the work stations in function and matched with track slab moulds of various models and specifications, the equipment on each work station is suspended and fixed on the ground surface by a support, and is matched with a plurality of movable running trolleys for conveying the track slab moulds and/or the track slabs, the running trolleys reciprocate or circularly move along a central track, and the track slab moulds and/or the track slabs are conveyed to the operation work stations according to the track slab manufacturing procedures. The central control room 25 realizes the control and monitoring of production equipment and process flow.
The type of the mould corresponds to the specification type of the ballastless track plate. And the production line meets the requirement of simultaneously carrying out circulation production by mixed knitting of two types of moulds, and can realize the production of changing any one of the two types of moulds into mixed knitting and doubling production of moulds of a third specification on line under the condition that the production line is not stopped. When a certain mould needs to be inserted for production, one of the two paths of devices in the two-path parallel operation can be automatically/manually adjusted to preset process conditions and adjustment positions, and the other path of devices continues to run in a non-stop flow-turning mode according to the production process.
Be provided with the driving track 401 that is used for small-size hoisting device to move, can realize that the transportation of steel reinforcement cage hoist and mount income position, mould rod iron.
The steam curing room 17 is composed of 8 or more closed steam curing modules with a group of moulds, and a plurality of closed steam curing modules can be arranged or expanded according to the productivity.
The single-group closed steam curing module is a door which can be automatically opened and closed by a central control room 25 at two ends of a track, and when 5-8 cast moulds are accumulated, the moulds are conveyed into a steam curing module channel by an operation trolley to be automatically and uniformly closed for steam curing.
A transition station 18 is arranged between the steam curing room 17 and the tension releasing station 19, and an equipment maintenance interval is reserved between the transition station 18 and the tension releasing equipment 19.
The running method (process flow) of the assembly line of the invention is as follows:
the first step is as follows: the running trolley transports the empty mold to a mold cleaning station 1 through the annular rail 101 or the auxiliary rail, and the mold is cleaned by a manual or mold cleaning device until the mold meets the requirements of the process specification;
the second step is that: the cleaned mould is transported to a mould detection station 2 by an operation trolley, detection is carried out by mould detection equipment according to detection standards, and the qualified mould enters a first embedded part and mould release agent mounting station 4 or a second embedded part and mould release agent mounting station 5 arranged on a second outer side rail 202; the unqualified die enters an unqualified die overhauling station 3 positioned on the first inner side track 301 to be inspected or maintained, and returns to a die detecting station 2 for secondary detection after maintenance;
the third step: coating a release agent on a qualified mold entering a first embedded part and release agent coating station 4 and/or a second embedded part and release agent coating station 5 and mounting the embedded parts;
the fourth step: a mould which is coated with a release agent and is provided with the embedded part is transported to a first steel cage positioning and pre-tightening station 7 on the annular track by an operation trolley on a first embedded part and release agent coating station 4, and the mould can be directly conveyed into a second steel cage positioning and pre-tightening station 8 through a second outer side track 202 or a first cross track 104 when the first steel cage positioning and pre-tightening station is in an overhauling or fault state; a mold which is coated with the release agent and is arranged on a second embedded part mounting and release agent coating station 5 is transported to a second steel cage positioning and pre-tightening station 8 which is positioned on a first outer side rail 201 by a running trolley, and when the second steel cage positioning and pre-tightening station is in a maintenance or fault state, a rail plate which is rotated out from the second embedded part mounting and release agent coating station 5 can be directly conveyed to the first steel cage positioning and pre-tightening station through an auxiliary rail;
the fifth step: entering a track plate mould of a first steel cage entering and pre-tightening station 7 and/or a second steel cage entering and pre-tightening station 8 to sequentially carry out steel cage entering, pre-tightening and steel bar installation;
and a sixth step: the die completing the operations of the first steel cage in-position and the pre-tightening station 7 is carried to a first tensioning station 11 by an operation trolley for tensioning, and when the first tensioning station 11 is in a maintenance or fault state, the die can enter a second tensioning station 10 through an auxiliary rail; the die completing the operation of the second steel cage positioning and pre-tightening station 8 is carried to a second tensioning station 10 by a running trolley for tensioning operation, and the second tensioning station can be directly transferred to a first tensioning station 11 when in a maintenance or fault state;
in the fourth, fifth and sixth steps, two moulds with different types and specifications can be arranged for production according to engineering requirements, and the production water of the other same station is influenced when the moulds are replaced. The adjusting device suitable for the moulds of different models and specifications is preset in each station device, and the setting can be quickly switched when the moulds of different models and specifications are replaced.
The seventh step: the mould transported from the first stretching station and/or the second stretching station enters an insulation detection station 12 on the annular track to perform insulation detection on the steel bar, and the steel bar is transported to a first vibration casting station 14 or a second vibration casting station 15 on the annular track by an operation trolley after the detection is qualified; and the die with unqualified insulation detection enters an unqualified insulation detection overhauling station 13 for adjustment, and then returns to the insulation detection station 12 for secondary detection.
Eighth step; the first vibration casting station 14 or the second vibration casting station 15 are arranged in series; and the mould entering the vibration pouring station performs material distribution and pouring according to a set program and performs intermittent vibration to complete the track slab forming operation.
The ninth step: the formed track slab and the track slab mold are transported to a roughening station 16 by an operation trolley, and roughening operation is carried out on the exposed surface of the track slab in the track slab mold by roughening equipment.
The tenth step; the track slab mold and the track slab after the galling operation enter the transfer section 26, and are sent into the steam curing module channel/steam curing room by the running trolley for automatic unified closed steam curing.
The eleventh step: and (3) conveying the track slab and the track slab die after the steam curing operation is finished to a first tension placing station 19 or a second tension placing station 20 to synchronously place the tension reinforcing steel bars in the track slab.
A transition station 18 is arranged between the steam curing room 17 and the first releasing station 19, and an equipment maintenance interval is reserved between the transition station 18 and the releasing equipment 19.
The twelfth step: and (3) conveying the track slab and the track slab die after the synchronous steel bar releasing to a demoulding station 21, demoulding the track slab by demoulding equipment, and collecting and transferring the die steel bar accessories by steel bar transferring equipment 22.
A tenth step; and (3) the demoulded track slab mold enters a mold cleaning station 1 to enter the next cycle operation, and the demoulded track slab is transported to an anchor sealing station 23 by an operation trolley to carry out anchor sealing operation.
The fourteenth step is that: and (4) carrying the rail plate after the anchor is sealed to the overturning equipment 24 by the operation trolley, overturning the rail plate on the overturning equipment 24 for 180 degrees in a large face, carrying out three-dimensional size detection on the surface of the rail plate, and warehousing qualified products.
In the first embodiment, when a new-specification mold needs to be inserted, the embedded part mold release agent coating device 4, the steel bar pre-tightening positioning device 8 and the tensioning device 10 stop being connected into the mold, the device automatically or manually performs corresponding adjustment and process presetting with the corresponding-specification mold, the process adjusting position 6 is provided with the new-specification mold prepared in advance, and the new-specification mold is carried to the embedded part mold release agent coating station 4 by the operation trolley, so that production line production of mixed weaving of the two molds is realized. When the new mold is about to enter the releasing and expanding station after the pouring and steaming of the new mold are finished, the equipment corresponding to the releasing and expanding station automatically or manually adjusts the corresponding specification mold in advance and presets the process, and the track slab mold is mixed and woven again after the releasing and expanding of the track slab mold are finished and enters the production line. At the same time, the overall operation of the production line does not need to be stalled.
The two-path double-station designed process equipment has the effect of function interchange.
In the second embodiment, when the production capacity is reduced, any one of the two double-station process equipment can be closed, including reducing the number of steam-curing module groups in the steam-curing room 17.
In the third embodiment, when the key stations are suspended due to reasons, the production line can continue to operate continuously without stopping, for example: when the equipment of the first steel cage in-position and pre-tightening station 7 stops working due to reasons, the track plate mold can detour through the first installation embedded part and mold release agent coating station 4, the second installation embedded part and mold release agent coating station 5, the second steel cage in-position and pre-tightening station 8, the second tensioning station 10 and the first tensioning station 11. For another example, when the equipment of the first tensioning station 11 is suspended for some reason, the equipment can be controlled to lift, so that the running trolley which flows out through the second tensioning station 10 can directly flow to the insulation detection equipment 12.
In the fourth embodiment, when the insulation detection is unqualified and cannot be repaired, the steel cage can be lifted away by entering the unqualified die maintenance station 3 through the unqualified insulation detection maintenance station 13, and then the steel cage enters the die detection station 2 for secondary detection and enters the production cycle.
The invention adopts a double-path and double-station design to improve and optimize the rapid strain capacity in production, and the equipment can be used. The track plate production line is compatible with the collinear operation of ballastless track plate moulds of various specifications to produce track plates, and can realize the collinear production of the moulds of two specifications simultaneously, so that the equipment utilization rate is improved, the equipment investment is reduced, the automatic equipment is intelligently controlled by a central control room, the operation capacity of the production line can be adjusted by adopting flexible process programs, the flexibility is higher, the design of double stations and the steam curing module (steam curing room) which can be increased and decreased can flexibly adjust the yield of the track plates to be matched with the engineering progress.
Claims (6)
1. A flexible flow production line for producing ballastless track plates by a pre-tensioning method comprises a plurality of operation stations arranged according to a process sequence, a track arranged along the operation stations and at least one operation trolley running on the track for transferring track plates and/or track plate molds, wherein the track is connected end to form an annular track, the flexible flow production line is characterized in that at least one auxiliary track connected with the annular track is arranged, the operation stations are arranged along the auxiliary track, the auxiliary track is arranged on the inner side and/or the outer side of the annular track and/or is crossed with the annular track, the track is a tangible solid track or an intangible ground walking route for the operation trolley to walk, the production stations are arranged along the walking track/route according to the process sequence, the annular track (101) is sequentially provided with a mold cleaning station (1) according to the process sequence, the device comprises a mould detection station (2), a first embedded part mounting and demolding agent coating station (4), a first steel cage positioning and pre-tightening station (7), a first tensile station (11), an insulation detection station (12), a first vibration pouring station (14), a second vibration pouring station (15), a roughening station (16), a steam maintenance station (17), a first release station (19) and a demolding station (21), an operation signal detection device which is provided with a central control room and connected with the central control room and mounted on each station, and a first outer side track (201) which is sequentially provided with a second embedded part mounting and demolding agent coating station (5), a second steel cage positioning and pre-tightening station (8) and a second tensioning station (10), the second embedded part mounting and pre-tightening station (8) and the second tensioning station (10) and the first mounting and demolding agent coating station (4), the first steel cage positioning and pre-tightening station (7) and the first drawing station (11) are arranged in parallel.
2. The flexible flow production line for producing the ballastless track plate by the pre-tensioning method according to claim 1, wherein a first inner side track (301), a second inner side track (302) and a third inner side track (303) are provided, the first inner side track is provided with a defective die maintenance station (3) adjacent to a die detection station, the first inner side track is further provided with a defective insulation detection maintenance station (13) adjacent to an insulation detection station (12), the second inner side track is provided with a second relaxation station (20), and the third inner side track is connected with an equipment maintenance area.
3. The flexible flow production line for producing the ballastless track plate by the pre-tensioning method according to claim 2, wherein a transition station is arranged between the steam curing station and the first tensioning station (19), and an equipment maintenance interval is reserved between the transition station and the first tensioning station (19).
4. The flexible flow production line for producing the ballastless track plate by the pre-tensioning method according to claim 2, wherein a first cross track (104) and a second cross track (105) are arranged, the second cross track is provided with an anchor sealing station (23) and a plate turning station (24), and the second cross track is connected with a track where the demolding station is located.
5. A flexible flow production line operation method for producing ballastless track plates by adopting a pre-tensioning method is characterized by comprising the following steps:
the first step is as follows: the running trolley carries the empty mold to a mold cleaning station (1) through the annular rail (101) or the auxiliary rail, and the mold is cleaned to meet the requirements of the process specification;
the second step is that: the cleaned mould is transported to a mould detection station (2) by an operation trolley, standardized detection is carried out by mould detection equipment, and the qualified mould enters a first mounting embedded part and mould release agent coating station (4) or a second mounting embedded part and mould release agent coating station (5) arranged on a second outer side track (202); the unqualified die enters an unqualified die overhauling station (3) positioned on the first inner side track (301) to be inspected or maintained, and the unqualified die returns to a die detecting station (2) to be detected again after being maintained;
the third step: the qualified mold entering a first embedded part and mold release agent coating station (4) and/or a second embedded part and mold release agent coating station (5) is coated with a mold release agent and installed with the embedded parts;
the fourth step: a mould which is coated with a release agent and is provided with the embedded part is delivered to a first steel cage positioning and pre-tightening station (7) positioned on an annular track by a running trolley from a first embedded part mounting and release agent coating station (4), and the mould can be directly conveyed into a second steel cage positioning and pre-tightening station (8) through a second outer side track (202) or a first cross track (104) when the first steel cage positioning and pre-tightening station is in a maintenance or fault state; a mold which is coated with a release agent and is arranged on a second embedded part mounting and release agent coating station (5) is carried to a second steel cage positioning and pre-tightening station (8) on a first outer side rail (201) by a running trolley, and when the second steel cage positioning and pre-tightening station is in a maintenance or fault state, a rail plate which is rotated out from the second embedded part mounting and release agent coating station (5) is directly conveyed to the first steel cage positioning and pre-tightening station through an auxiliary rail;
the fifth step: entering a track plate mould of a first steel cage entering and pre-tightening station (7) and/or a second steel cage entering and pre-tightening station (8) to sequentially carry out steel cage entering, pre-tightening and steel bar installation;
and a sixth step: the die completing the operation of the first steel cage in-position and pre-tightening station (7) is transported to a first tensioning station (11) by an operation trolley for tensioning operation, and when the first tensioning station (11) is in a maintenance or fault state, the die can enter a second tensioning station (10) through an auxiliary rail; the die completing the operation of the second steel cage in-position and pre-tightening station (8) is carried to a second tensioning station (10) by the running trolley for tensioning operation, and when the second tensioning station is in a maintenance or fault state, the die can be directly transferred to a first tensioning station (11);
the seventh step: the mould transported from the first stretching station and/or the second stretching station enters an insulation detection station (12) on the annular track to perform insulation detection on the steel bar, and the steel bar is transported to a first vibration casting station (14) or a second vibration casting station (15) on the annular track by an operation trolley after the detection is qualified; the die with unqualified insulation detection enters an unqualified insulation detection maintenance station (13) for adjustment, and then returns to an insulation detection station (12) for secondary detection;
eighth step; the mould entering the vibration pouring station performs material distribution and pouring according to a set program and performs intermittent vibration to complete the track slab forming operation;
the ninth step: the formed track plate and track plate mould is transported to a roughening station (16) by an operation trolley, and roughening operation is carried out on the exposed surface of the track plate in the track plate mould by roughening equipment;
the tenth step; the track slab mold and the track slab which finish the galling operation are transported to a steam curing room (17) by an operation trolley for steam curing operation;
the eleventh step: the rail plate and the rail plate mould after the steam curing operation are sent to a first tension placing station (19) or a second tension placing station (20) to synchronously place the tension reinforcing steel bars in the rail plate;
the twelfth step: the rail plate and the rail plate mold after synchronous steel bar releasing are conveyed to a demolding station (21) to be demolded by demolding equipment, and the steel bar accessories of the mold are collected and transported by steel bar transferring equipment (22);
a tenth step; the demoulded track plate mould enters a mould cleaning station (1) to enter the next cycle operation, and the demoulded track plate is transported to an anchor sealing station (23) by an operation trolley to carry out anchor sealing operation;
the fourteenth step is that: and (4) carrying the rail plate after the anchor is sealed to a turnover device (24) by a running trolley, turning the upper surface of the rail plate for 180 degrees in a large scale, carrying out three-dimensional size detection on the surface of the rail plate, and warehousing qualified products.
6. The operation method of the flexible flow production line for producing the ballastless track plate by the pre-tensioning method according to claim 5, wherein the operation method comprises the following steps: the device comprises a first installation embedded part and release agent coating station (4), a second installation embedded part and release agent coating station (5), a first steel cage in position and pre-tightening station (7), a second steel cage in position and pre-tightening station (8), a first tensioning station (11), a second tensioning station (10), a first releasing station (19) and a second releasing station (20), and all equipment corresponding to the first installation embedded part and release agent coating station and the second installation embedded part and the release agent coating station, are provided with adjusting positions matched with moulds of different specifications and preset process conditions so as to adapt to the adjustment of moulds of multiple specifications at any time.
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| CN201710593953.7A CN107225671B (en) | 2017-07-20 | 2017-07-20 | Flexible flow production line for producing ballastless track plate by pre-tensioning method |
| PCT/CN2018/075606 WO2019015305A1 (en) | 2017-07-20 | 2018-02-07 | Flexible flow production line for producing ballastless track slab by means of pre-tensioning method |
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| CN201710593953.7A CN107225671B (en) | 2017-07-20 | 2017-07-20 | Flexible flow production line for producing ballastless track plate by pre-tensioning method |
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| CN107225671B (en) * | 2017-07-20 | 2021-04-13 | 山西高行液压股份有限公司 | Flexible flow production line for producing ballastless track plate by pre-tensioning method |
| CN108326824B (en) * | 2017-12-27 | 2024-01-02 | 北京动仿航泰科技有限公司 | Matrix type track system, associated loop type production line and production method thereof |
| CN108214875B (en) * | 2018-01-23 | 2019-08-09 | 博联罗伊斯(苏州)工业设备制造有限公司 | A kind of track plates automatic production line |
| CN109203211B (en) * | 2018-10-12 | 2024-01-12 | 广州建筑产业研究院有限公司 | Assembly line for component compatible production |
| CN109773952B (en) * | 2019-01-29 | 2023-09-15 | 中交武汉港湾工程设计研究院有限公司 | Short line matching segment beam circulating flow production line and production method thereof |
| CN111186012A (en) * | 2020-01-17 | 2020-05-22 | 中铁三局集团有限公司 | Automatic production line for railway track slabs |
| CN113910445B (en) * | 2021-09-26 | 2022-12-06 | 中铁九局集团有限公司 | High-speed railway pre-tensioned track slab production system and production method thereof |
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| CN207373420U (en) * | 2017-07-20 | 2018-05-18 | 山西高行液压股份有限公司 | Pre-tensioning system produces the flexible flow production line of fragment-free track slab |
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| JPH03120010A (en) * | 1989-10-03 | 1991-05-22 | Shinkai Kogyo Kk | Molding apparatus |
| CN1865593A (en) * | 2006-05-05 | 2006-11-22 | 欧阳炎 | Bidirectional pretensioning method prestressed concrete railway board and assembly machine sets method production process |
| CN106466882B (en) * | 2016-08-23 | 2019-02-01 | 山东高速轨道设备材料有限公司 | Pretensioning prestressed concrete track plates unit pipeline automation manufacturing technology |
| CN106738283B (en) * | 2016-12-08 | 2018-05-18 | 山西高行液压股份有限公司 | High speed railway fragments-free track slab pre-tensioning system flowing water unit production line |
| CN107225671B (en) * | 2017-07-20 | 2021-04-13 | 山西高行液压股份有限公司 | Flexible flow production line for producing ballastless track plate by pre-tensioning method |
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| CN207373420U (en) * | 2017-07-20 | 2018-05-18 | 山西高行液压股份有限公司 | Pre-tensioning system produces the flexible flow production line of fragment-free track slab |
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