CN108000694B - Pretensioned prestressed concrete track slab production line maintenance system and application thereof - Google Patents
Pretensioned prestressed concrete track slab production line maintenance system and application thereof Download PDFInfo
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- CN108000694B CN108000694B CN201810009419.1A CN201810009419A CN108000694B CN 108000694 B CN108000694 B CN 108000694B CN 201810009419 A CN201810009419 A CN 201810009419A CN 108000694 B CN108000694 B CN 108000694B
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- 238000012423 maintenance Methods 0.000 title claims abstract description 103
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 47
- 239000011513 prestressed concrete Substances 0.000 title claims abstract description 28
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 152
- 238000001816 cooling Methods 0.000 claims abstract description 49
- 238000001514 detection method Methods 0.000 claims abstract description 11
- 239000002344 surface layer Substances 0.000 claims abstract description 10
- 238000000034 method Methods 0.000 claims description 54
- 238000005507 spraying Methods 0.000 claims description 46
- 239000007921 spray Substances 0.000 claims description 45
- 230000008569 process Effects 0.000 claims description 27
- 238000010438 heat treatment Methods 0.000 claims description 18
- 238000009423 ventilation Methods 0.000 claims description 15
- 230000007613 environmental effect Effects 0.000 claims description 13
- 230000001502 supplementing effect Effects 0.000 claims description 13
- 238000002360 preparation method Methods 0.000 claims description 7
- 238000012544 monitoring process Methods 0.000 claims description 6
- 230000002093 peripheral effect Effects 0.000 claims description 4
- 230000009467 reduction Effects 0.000 claims description 4
- 239000011810 insulating material Substances 0.000 claims 1
- NJPPVKZQTLUDBO-UHFFFAOYSA-N novaluron Chemical compound C1=C(Cl)C(OC(F)(F)C(OC(F)(F)F)F)=CC=C1NC(=O)NC(=O)C1=C(F)C=CC=C1F NJPPVKZQTLUDBO-UHFFFAOYSA-N 0.000 description 10
- 238000013461 design Methods 0.000 description 8
- 230000005540 biological transmission Effects 0.000 description 5
- 238000010276 construction Methods 0.000 description 5
- 239000004567 concrete Substances 0.000 description 4
- 230000007547 defect Effects 0.000 description 4
- 239000012774 insulation material Substances 0.000 description 3
- 230000008054 signal transmission Effects 0.000 description 3
- 238000010025 steaming Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000012806 monitoring device Methods 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 239000008236 heating water Substances 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 238000009417 prefabrication Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000000630 rising effect Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- 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
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- Engineering & Computer Science (AREA)
- Structural Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- On-Site Construction Work That Accompanies The Preparation And Application Of Concrete (AREA)
- Lining And Supports For Tunnels (AREA)
Abstract
The utility model belongs to the production of track slabs, in particular to a pretensioned prestressed concrete track slab production line maintenance system and application thereof. The curing system comprises a steam curing room which is arranged between working rails matched with the die and provided with an automatic door, a nozzle which is arranged in the steam curing room and is connected with a constant temperature water supply device, and a temperature detection and temperature control device which is connected with a central control device; the ground in the steam curing room is provided with a walking track and a circulation traction device for traction of the die, the walking track is connected with a working track outside the steam curing room, and the temperature and humidity detection device comprises a core temperature and humidity sensor, a surface layer temperature and humidity sensor and an environment temperature and humidity sensor; the temperature control device comprises a steam supply device and an air cooling device. The utility model effectively solves the technical problems that the maintenance means is single, the existing standard requirements cannot be met, and the like in the prior art, has the advantages of better meeting the existing standard requirements, realizing high-efficiency assembly line production and being easy to realize automatic control.
Description
Technical Field
The utility model belongs to the production of track slabs, in particular to a pretensioned prestressed concrete track slab production line maintenance system and application thereof.
Background
In the production process of the track slab for the construction of the ballastless track of the high-speed railway, the working procedures of steam curing and sprinkling and spraying curing are needed after the concrete pouring is completed. The main purpose of steam curing is to quickly improve the strength of the track slab, shorten the production period, improve the product quality and save the production cost. Meanwhile, the problems of dry shrinkage, cracks and warping caused by overhigh temperature and humidity of the track slab in the steam curing process are prevented, and the spraying water supplementing curing process is added in the curing process to improve the quality of products, so that the method is one of key factors of the quality in the whole track slab construction technology.
CRTS track slabs are classified into rear Zhang Fa, II, III type and III type pretensioned track slabs with independent intellectual property rights. The production mode is divided into a post Zhang Fashan mould production mode and a pretensioning method pedestal production mode, but the steaming mode is basically consistent, and the closed curing space is formed by manually covering tarpaulin or a steaming shed in a manually-operated mode in a state that the mould is not moved in situ after the prefabrication of concrete is completed, a steam pipeline is preset in the shed, a temperature and humidity sensor is manually placed to collect temperature and humidity, and the output of steam is controlled through the collected temperature and humidity so as to achieve the curing of the track slab. The spray water supplementing maintenance is carried out by adopting a pure manual watering mode in a single-mode production mode, and the pretensioned pedestal type adopts a mode of timing manual watering or manual pipe distribution semi-automatic control for water spraying maintenance. The prior art has certain defects: firstly, the whole steam curing process has complicated equipment, more single working sites, more manpower and high labor intensity; secondly, the occupied area of a mode steam curing area produced by adopting a fixed bench or a fixed single mode is large, so that the occupied area of a pipeline arrangement and a workshop is greatly increased, the field construction cost is increased, the subsequent equipment is difficult to reuse, the land is difficult to re-plough, and great waste is caused; thirdly, the implementation process of the steam curing process is complicated, manual operation is performed in many links, the degree of human interference is high, and the degree of automation is low; fourthly, spraying and water supplementing maintenance cannot be performed in time in the steam curing process, and when water is sprayed in the post Zhang Shan mold production process, the tarpaulin needs to be lifted for manual sprinkling, and meanwhile, the temperature and humidity in the tarpaulin are changed severely; although the construction of the pedestal method is greatly improved, the hose is still manually placed on the surface of the track plate every time, and is manually removed after the hose is completed, so that the degree of automation is not high. Meanwhile, no matter manual or semi-automatic sprinkling is carried out in two procedures separated from the steam curing equipment, the water can not be timely supplemented according to the water shortage degree of the surface of the track plate in the steam curing process, and the whole steam curing process is imperfect; fifthly, in the steam curing process, because the cover-lifting tarpaulin is required to be manually lifted for inspection or water spraying, a large amount of human intervention factors are doped, and the requirements of the existing standard CRTSIII plate type ballastless track pretensioning method prestressed concrete track slab (Q/CR 567-2017) on the temperature and humidity control of the steam curing process cannot be strictly met in the actual process.
In order to adapt to the current vigorous competition of the international high-speed railway construction, the development of a more advanced and scientific intelligent streamline production technology of the pretensioned track plate is imperative. The steam curing process for the traditional post Zhang Shan die or bench type production cannot meet the process requirements of a flow machine set method.
Patent documents retrieved by the applicant include:
1. the utility model patent application with the application number of 201410619250.3 discloses a track slab steam curing system, the main technical scheme is that the system comprises a curing shed, a pedestal, a heating system, a control system and a ventilation cooling system, wherein the curing shed is arranged above the pedestal, the heating system comprises a steam pipeline, a boiler, an electromagnetic valve and a spray hole, the steam pipeline is paved below the pedestal, the electromagnetic valve and the spray hole are arranged on the steam pipeline, the electromagnetic valve is connected with the spray hole, the boiler is connected with the steam pipeline, the control system comprises a temperature and humidity monitoring device, a wireless transmission device and a control device, the temperature and humidity monitoring device is connected with the control device through the wireless transmission device, the ventilation cooling system comprises a fan and an air pipe, the air pipe is paved on the ceiling of the curing shed, and the fan is connected with the air pipe. The main problems of the prior art are that the application environment is limited, the pedestal type production mode can be aimed only, the pedestal type production mode can not be used universally, and the prior specification requirements can be met; secondly, the pipeline arrangement mode has defects, because the steam curing system is a fixed pipeline at the bottom of the die, steam is upwards sprayed out, and because the distance between the steam curing system and the pipeline is relatively short when the die is installed, the local temperature and the humidity of the bottom plate of the die are too high in the actual steam curing process, the requirement on curing temperature and humidity in the specification is not easy to meet, and the adjustment is relatively difficult; thirdly, a Zigbee wireless transmission mode is adopted, and because the transmission mode is a receiving multi-point transmission mode, the acquisition is disordered when the sensors are too much, meanwhile, the wireless module is powered by a battery, the electric quantity using degree of the battery cannot be ensured, and a plurality of unnecessary defects such as data loss, disordered and the like occur under the working condition; fourthly, only steam curing can be realized, and the function is single.
2. The utility model patent number 201620856872.2 discloses a track slab steam curing constant temperature water supplementing device, which mainly adopts the technical scheme that the device comprises a water tank, wherein the water tank is a constant temperature automatic heating water tank, the output end of the water tank is provided with a water circulating system, the water circulating system comprises a water circulating main pipeline and a circulating pump, the water circulating main pipeline is provided with a plurality of branch pipelines, the branch pipelines are respectively arranged beside each production pedestal, the water tank circulates water through the circulating pump, and the semi-automatic water supplementing operation in the track slab steam curing process is only realized, the required production mode is pedestal production, and the production mode of assembly line cannot be realized. Meanwhile, the system can only complete water supplementing maintenance of the track plate and cannot be well combined with steam maintenance, so that the full-automatic coverage of the steam curing process is realized.
To the extent that the applicant knows, no report or existing product meets the condition requirement for track slab maintenance operation in the existing pretensioned concrete track slab of the CRTSIII type ballastless track of the high-speed railway (Q/CR 567-2017) and the temporary technical requirement of the pretensioned concrete track slab of the CRTSIII type ballastless track of the high-speed railway (running water machine set method) (TK/GW 156-2016) is disclosed.
Disclosure of Invention
The utility model aims to provide a curing system of a pretensioned prestressed concrete track slab production line and application thereof, and the curing operation in track slab production can be completed by adopting the curing system of the utility model, so that the technical requirements in the existing specifications can be met.
The utility model has the following overall technical concept:
the curing system of the pretensioned prestressed concrete track slab production line comprises a steam curing room capable of accommodating a die, wherein a spray head and a spray nozzle which are connected with a steam control output device, a ventilation cooling device and a constant temperature water supply device, a temperature and humidity detection device, a die self-walking device and a temperature and humidity control device are arranged in the steam curing room; the automatic steam curing machine is characterized in that a working rail matched with a die is arranged in the steam curing room, and automatic doors communicated with a central control device are arranged on the side walls of the two ends of the steam curing room; the ground in the steam curing room is provided with a walking track matched with the mould and a circulation traction device for traction of the mould, and the walking track is connected with a working track outside the steam curing room to form a mould self-walking device; the temperature and humidity detection device comprises a core temperature sensor and a surface layer temperature and humidity sensor, wherein the core temperature sensor and the surface layer temperature and humidity sensor are used for detecting the temperature and humidity of a track plate in a die, and the environment temperature and humidity sensor is used for detecting the temperature and humidity in a steam curing room; the temperature and humidity control device comprises a steam pipeline, a water spraying pipeline and an air cooling device, wherein the steam pipeline is opened in the steam curing room and connected with a peripheral steam supply device.
The applicant needs to explain that the automatic door is used for keeping the ambient temperature and humidity in the steam curing room in the curing process of the track plate, and the implementation mode can adopt a driving mechanism in various modes to realize the automatic opening or closing of the automatic door in a flat-moving, sliding or rotating mode, and the automatic door does not deviate from the technical essence of the utility model, so that the automatic door belongs to the prior art and is not repeated herein.
The application of the pretensioned prestressed concrete track slab production line maintenance system in pretensioned prestressed concrete track slab maintenance.
The specific technical concept of the utility model is as follows:
the steam supply device mainly heats the water tank and provides steam for the steam curing room, and can conveniently realize automatic control, can adopt multiple pressure vessels, control valves and pipelines connected with a steam source to realize on the premise of meeting the requirements, wherein the preferred technical realization mode is that the steam supply device selects a branch air cylinder with an inlet communicated with a main steam pipe of a boiler, an outlet of the branch air cylinder is connected with an auxiliary steam pipe, and a steam control valve group is assembled on the auxiliary steam pipe.
The more preferable technical implementation mode is that the steam pipeline comprises steam branch pipes which are arranged at the left side and the right side of the walking track in the vertical direction, steam spray holes which are arranged at intervals in the vertical direction and correspond to the outer surface of the die are formed in the steam branch pipes, and the other ends of the steam branch pipes are communicated with the steam supply device through steam auxiliary pipes and steam control valve groups. The steam control valve group comprises a manual valve and an electric control valve, the electric control valve is an gradually-opened electric valve instead of a conventional direct-opening electromagnetic valve, the control precision of a maintenance curve and the softness of change are ensured, the steam control valve group is suitable for field environments, and the service life of devices is prolonged and the maintenance is convenient.
The structural design of the steam jet holes mainly avoids local overheating of the mould caused by too close distance between the steam jet holes and the mould in the steam curing room on the premise of supplying steam and heating the steam in the steam curing room, so that the temperature adjustment in the track plate curing process is difficult. A more preferred technical implementation is α1=30°, α2=120°.
The constant temperature water supply device mainly aims at providing constant temperature water meeting the requirements of maintenance corresponding stage specifications for the nozzle, and meanwhile, the control is convenient to realize.
In order to facilitate the water in the water tank with the temperature higher than the requirement to be cooled, and facilitate the realization of automatic control, a more preferable technical realization mode is that the constant temperature water supply device also comprises a water supplementing pipeline communicated with the water tank, and the water supplementing pipeline is provided with a self-water supplementing control device connected with the central control device.
In order to facilitate relatively uniform water spray maintenance on the track plate and simultaneously facilitate automatic control, the preferred technical implementation mode is that the spray nozzle adopts an atomizing spray nozzle which is communicated with the constant-temperature water supply device through a water spray pipeline, a booster pump and a spray control valve group.
On the premise of meeting the functional requirement, in order to avoid heat loss of constant-temperature water in the pipeline, the design of the water spraying pipeline should take a shorter arrangement path as one of requirements, and the pipeline design is optimized by combining corresponding facilities, wherein the water spraying pipeline comprises a water spraying branch pipe and a water spraying auxiliary pipe, wherein the two ends of the water spraying branch pipe are communicated with an atomizing nozzle and a constant-temperature water supply device, and the water spraying branch pipe and the water spraying auxiliary pipe are connected end to end.
For being convenient for to evaporating the indoor environment cooling of foster room, the more preferred technical realization mode of air cooling device is, including setting up in evaporating the ventilation window at foster room top, the ventilation window passes through the fan intercommunication of air cooling pipeline and peripheral hardware.
In order to detect the temperature of the environment outside the steam curing room conveniently, so as to facilitate dynamic control of curing, the preferable technical scheme is that the temperature and humidity detection device comprises a temperature and humidity sensor arranged outside the steam curing room.
In order to facilitate the drainage of condensed water in the steam curing room, reduce the backlog of the condensed water and the absorption of heat and keep the relative dryness of the environment in the steam curing room, the preferable technical implementation mode is that the earth surface in the steam curing room is provided with a drainage ditch communicated with the outside.
In order to facilitate quick assembly and signal transmission of the sensor and ensure signal transmission quality so as to realize accurate control, the preferred technical implementation mode is that the core temperature sensor, the surface temperature and humidity sensor and the environment temperature and humidity sensor are connected with the central control device in a wired mode after being positioned and fixed; wherein the core temperature sensor is wired using a quick connect. The applicant needs to say that, because the core temperature sensor is placed in the track slab in a pre-buried mode and is disposable in the track slab pouring process in the existing manufacturing process, the functions are realized by manually connecting the sensor with the quick-mounting plug in the mode, and the quick-mounting plug is detached or cut off after maintenance is completed. Because the quick-mounting connector belongs to the prior art and has various specifications and types of commercial products, the applicant does not need to describe the structure of the quick-mounting connector again.
In order to facilitate more accommodating moulds in the steam curing room and facilitate the connection of curing procedures and the transportation of the moulds so as to improve work efficiency, the preferable technical implementation mode is that the walking tracks are distributed in parallel at intervals in the steam curing room, and each group of walking tracks are sealed and isolated by using a heat insulation wall.
In order to facilitate the maintenance of the environmental temperature and humidity in the steam curing room, the steam curing room is constructed by adopting a heat insulation material in a preferred implementation mode. Including but not limited to, the prior art means such as building components, surface materials or coatings with heat insulation function are adopted without departing from the technical spirit of the utility model.
The application of the pretensioned prestressed concrete track slab production line maintenance system in pretensioned prestressed concrete track slab maintenance comprises the following process steps:
A. track slab maintenance preparation
The mould after pouring and vibrating of the track slab is pulled into a steam curing room by a circulation pulling device along a walking track, an automatic door is correspondingly opened or closed when the mould is pulled each time, and the mould is sprayed with atomized water after entering the steam curing room; before spraying, the temperature is monitored and compared in real time through an environment temperature and humidity sensor and a water tank temperature sensor, so that the water temperature is ensured to be basically consistent with the temperature in the steam curing room;
B. standing maintenance of track slab
When the mold on the travelling track in the steam curing room is full and the automatic door is completely closed, the automatic door enters a track plate standing curing stage, a central control device starts timing, the temperature is monitored in real time through a core temperature sensor, a surface temperature and humidity sensor and a water tank temperature sensor and is compared with the temperature, a temperature setting water supply device is controlled by the central control device to spray water to the surface of the track plate in the mold for standing curing through a nozzle, and the requirement of the standard on the track plate standing curing is met;
C. track slab heating maintenance
C, carrying out heating maintenance after the track slab is kept stand and maintained, carrying out water spraying maintenance according to the same requirements as those of the step B, and simultaneously carrying out environmental heating on a steam curing room by a central control device through controlling a steam supply device to spray steam through steam spray holes, wherein an environmental temperature and humidity sensor, a core temperature sensor, a surface temperature and humidity sensor and a temperature and humidity sensor acquire temperatures of corresponding areas in real time, and dynamically controlling the temperature in the steam curing room according to technological parameters preset by the central control device so as to meet the requirements of the regulation on the heating maintenance of the track slab;
D. constant temperature maintenance of track slab
C, carrying out constant-temperature maintenance when the temperature rise maintenance of the track slab reaches the requirement, carrying out water spraying maintenance according to the same requirement as the step B, and acquiring the temperature of a corresponding area in real time by a central control device according to an environment temperature sensor, a core temperature sensor, a surface temperature humidity sensor and a temperature humidity sensor, wherein the constant-temperature maintenance requirement is met through the control of a temperature control device;
E. track slab cooling maintenance
And C, entering a cooling maintenance stage after the constant-temperature maintenance of the track slab is completed, carrying out water spraying maintenance according to the same requirements as those of the step B, closing the steam supply device, and controlling the operation of the air cooling device by the central control device through monitoring the temperature of each sensor so that the temperature meets the cooling maintenance condition requirements in the standard requirements.
F. Maintenance of track slabs
When the automatic door is opened after cooling maintenance is finished, the molds are sequentially conveyed to an external working rail along a walking rail by a circulation traction device, and the next batch of molds to be maintained sequentially enter a next track slab maintenance procedure.
In order to improve the work efficiency, the preferred technical implementation mode of the track slab maintenance preparation procedure is that in the step A, after the mold on one walking track in the steam curing room is full, the automatic door is thoroughly closed to form a maintenance space, and simultaneously, the mold is pushed into the adjacent walking track in the steam curing room to finish the preparation of track slab maintenance.
The track slab standing maintenance is preferably realized by the technical implementation mode that the temperature control method of the constant-temperature water supply device in the step B is that when the water temperature of the water tank is lower than the environmental temperature in the steam curing room, the central control device controls the steam supply device to heat the water in the water tank; when the water temperature in the water tank is higher than the environmental temperature in the steam curing room, the central control device is filled with water and cooled through the self-water-supplementing control device.
The track slab temperature rising maintenance is preferably realized by the technical implementation mode that the temperature control method in the step C is that the temperature in the sub-cylinder reaches the requirement and the boiler supplies steam to the sub-cylinder through a main steam pipe, the central control device controls the opening of a steam control valve group, and steam enters the environment temperature in the steam curing room through a steam auxiliary pipe, a steam branch pipe and a steam spray hole.
The track plate constant temperature maintenance is preferably realized by the technical implementation mode that the temperature control method in the step D is that when the temperature in the steam curing room needs to be raised, the central control device controls the steam control valve group to be opened, and steam enters the steam curing room through the steam auxiliary pipe, the steam branch pipe and the steam spray hole to raise the ambient temperature; when the temperature in the steam curing room needs to be reduced, the air cooling device and the constant temperature water supply device are opened, and the central control device controls the fan to input cool air through the air cooling pipeline and the ventilation window so as to realize the temperature reduction in the steam curing room; the constant-temperature water spraying device sprays water to the surface of the track plate in the die through the nozzle to realize the cooling of the track plate, and the cooling speed is less than or equal to 15 ℃/h in the cooling process.
The specific requirement of the track slab cooling maintenance is that in the step E, when the temperatures acquired by the surface temperature and humidity sensor and the environment temperature and humidity sensor are basically the same, and the temperature difference between the surface temperature and humidity sensor and the core temperature and humidity sensor is not more than 15 ℃, the track slab cooling maintenance is completed.
The applicant needs to say that:
in the description of the present utility model, the positional or positional relationship indicated by the terms such as "outer", "two ends", "side walls", "left and right", "longitudinal", "top", etc. are based on the positional or positional relationship shown in the drawings, are merely for the convenience of simplifying the description of the present utility model, and do not indicate or imply that the apparatus or element in question must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as limiting the present utility model.
The essential characteristics and remarkable technical progress of the utility model are as follows:
1. the working rail capable of containing the die and the circulation traction device are adopted as main means for die station conversion in the maintenance process, and the technical requirements of the existing specifications for temperature monitoring and covering of the same batch of track boards in the track board maintenance are better met on the premise that the production line is convenient to realize rapid production and the maintenance work efficiency is effectively improved by combining the structural design of the core temperature sensor, the surface temperature and humidity sensor and the environment temperature and humidity sensor which are connected with the central control device.
2. The adoption of the constant-temperature water supply device and the temperature and humidity control device effectively ensures strict temperature and humidity control requirements of various procedures in the conventional standard maintenance process, and is convenient for realizing automatic control.
3. The steam supply device is matched with the structural design of the constant temperature water supply device, so that the constant temperature water supply in the water spraying operation can be effectively ensured, the water spraying operation and the steam curing in the curing operation can be simultaneously carried out, and the technical defect of single curing means in the prior art is effectively overcome.
4. The structural design of the split cylinder, the corresponding pipeline and the control valve is convenient for realizing automatic control on the premise of meeting the steam supply condition. By combining with the structural design of the orientation of the steam holes, the local temperature rise of the die is avoided, and the uniform temperature rise of the internal environment of the steam curing room is realized.
5. The steam curing house is constructed by using heat insulation materials, and adopts the structural design of an automatic door and a drainage ditch, so that the temperature of the internal environment is well maintained, and the energy consumption caused by temperature regulation is saved on the premise of being convenient for controlling and adjusting the temperature.
6. The sensor is connected with the central control device through the quick connector and the wire electricity, and the stability of signal transmission is effectively ensured on the premise of meeting the requirement of quick and effective assembly.
7. By adopting the maintenance system and the maintenance process thereof, the maintenance system and the maintenance process thereof can effectively meet the requirements of the existing specifications on the maintenance conditions of the track slabs, and simultaneously are convenient for realizing automatic control and assembly line production.
Drawings
FIG. 1 is a schematic layout of a curing system of the present utility model.
FIG. 2 is a cross-sectional view of the maintenance system according to the present utility model.
Reference numerals in the drawings are as follows:
1. steaming and curing room; 2. an atomizing nozzle; 3. an air-cooled pipeline; 4. an environmental temperature and humidity sensor; 5. a water spray branch pipe; 6. a steam branch pipe; 7. steam jet holes; 8. a blower; 9. a steam auxiliary pipe; 10. a gas separation cylinder; 11. a steam main pipe; 12. a steam control valve group; 13. a water spraying auxiliary pipe; 14. a spray control valve group; 15. a booster pump; 16. a water tank; 17. a core temperature sensor; 18. a surface temperature and humidity sensor; 19. A circulation traction device; 20. a mold; 21. a walking rail; 22. a drainage ditch; 23. a self-water-replenishing control device; 24. a water tank temperature sensor; 25. an automatic door; 26. a ventilation window; 27. and a temperature and humidity sensor.
Detailed Description
The present utility model will be further described with reference to the following examples, but the scope of the present utility model is defined by the appended claims, and any equivalent technical means according to the description may be substituted without departing from the scope of the present utility model.
The overall concept of the curing system in this embodiment is as shown in the figure, and the curing system comprises a steam curing room 1 capable of accommodating a mold 20, wherein a spray head and a spray nozzle which are connected with a steam control output device, a ventilation cooling device and a constant temperature water supply device, a temperature and humidity detection device, a mold self-walking device and a temperature and humidity control device which are connected with a central control device are arranged in the steam curing room 1; the steam curing room 1 is internally provided with a working track matched with the die 20, and the side walls at two ends of the steam curing room 1 are provided with automatic doors 25 communicated with a central control device; the ground in the steam curing room 1 is provided with a walking track 21 which is matched with the die 20 and a circulation traction device 19 which is used for traction of the die 20, and the walking track 21 is connected with a working track outside the steam curing room 1 to form a die self-walking device; the temperature and humidity detection device comprises a core temperature sensor 17 and a surface layer temperature and humidity sensor 18, wherein the core temperature sensor 17 and the surface layer temperature and humidity sensor 18 are used for detecting the temperature and humidity of a track plate core and the surface in the die 20, and the environment temperature and humidity sensor 4 is used for detecting the temperature and humidity in the steam curing room 1; the temperature and humidity control device comprises a steam pipeline, a water spraying pipeline and an air cooling device, wherein the steam pipeline is opened in the steam curing room 1 and connected with a peripheral steam supply device.
The steam supply device selects a branch air cylinder 10 with an inlet communicated with the boiler through a main steam pipe 11, the outlet of the branch air cylinder 10 is connected with an auxiliary steam pipe 9, and the auxiliary steam pipe 9 is provided with a steam control valve group 12.
The steam pipeline comprises steam branch pipes 6 which are arranged on the left side and the right side of the walking track 21 in the vertical direction, steam spray holes 7 which are arranged on the steam branch pipes 6 in the vertical direction at intervals and correspond to the outer surface of the die 20, and the other ends of the steam branch pipes 6 are communicated with a steam supply device through steam auxiliary pipes 9 and a steam control valve group 12.
The steam jet holes on two sides of the track are uniformly distributed on two sides of the track, the opening directions of the steam jet holes face the track direction and form included angles alpha 1 and alpha 2 with the walking track, alpha 1 = 30 degrees and alpha 2 = 120 degrees.
The constant temperature water supply device comprises a water tank, a water tank temperature sensor which is arranged in the water tank and connected with the central control device, and a steam pipeline and a control valve which are communicated with the steam supply device are connected in the water tank.
The constant temperature water supply device also comprises a water supplementing pipeline with an outlet communicated with the water tank 16, and a self-supplementing water control device 23 connected with the central control device is arranged on the water supplementing pipeline.
The spray nozzle is an atomizing spray nozzle 2, and the atomizing spray nozzle 2 is communicated with the constant-temperature water supply device through a water spray pipeline, a booster pump 15 and a spray control valve group 14.
The water spraying pipeline comprises a water spraying branch pipe 5 and a water spraying auxiliary pipe 13, wherein the two ends of the water spraying branch pipe are communicated with the atomizing nozzle 2 and the constant-temperature water supply device, and the water spraying branch pipe and the water spraying auxiliary pipe are connected end to end.
The air cooling device comprises a ventilation window 26 arranged at the top of the steam curing room 1, and the ventilation window 26 is communicated with an external fan 8 through an air cooling pipeline 3.
The temperature and humidity detection device comprises a temperature and humidity sensor 27 arranged outside the steam curing chamber 1.
The surface between the travelling rails 21 in the steam curing room 1 is provided with a drainage ditch 22 communicated with the outside.
The core temperature sensor 17, the surface temperature and humidity sensor 18 and the environment temperature and humidity sensor 4 are electrically connected with the central control device through a quick connector.
The walking tracks 21 are distributed in parallel and at intervals in the steam curing room 1.
The steam curing house 1 is constructed by adopting heat insulation materials.
The application of the pretensioned prestressed concrete track slab production line maintenance system in pretensioned prestressed concrete track slab maintenance comprises the following process steps:
A. track slab maintenance preparation
The die 20 after pouring and vibrating of the track slab is pulled into the steam curing room 1 along the travelling track 21 by the circulation pulling device 19, the automatic door 25 is correspondingly opened or closed when the die 20 is pulled each time, and atomized water spraying is carried out after the die 20 enters the steam curing room 1; before spraying, the temperature is monitored and compared in real time through an environment temperature and humidity sensor 4 and a water tank temperature sensor 24, so that the water temperature is ensured to be basically consistent with the temperature in the steam curing room 1;
B. standing maintenance of track slab
When the mold 20 in the travelling rail 21 in the steam curing room 1 is full and the automatic door 25 is thoroughly closed, entering a rail plate standing curing stage, starting timing by the central control device, monitoring the temperature in real time through the core temperature sensor 17 and the water tank temperature sensor 24 and comparing the temperature, and controlling the constant-temperature water sprinkling device to spray water to the surface of the rail plate in the mold 20 through the nozzle by the central control device to perform standing curing, so that the requirement of the standard on the rail plate standing curing is met;
C. track slab heating maintenance
C, after the track slab is kept stand and cured, carrying out heating curing, carrying out water spraying curing according to the same requirements as those of the step B, and simultaneously carrying out environmental heating on the steam curing room 1 by controlling the steam supply device to spray steam through the steam spray holes 7 by the central control device, wherein the environmental temperature and humidity sensor 4, the core temperature sensor 17, the surface layer temperature and humidity sensor 18 and the temperature and humidity sensor 27 acquire the temperatures of corresponding areas in real time, dynamically controlling the temperature in the steam curing room 1 according to the technological parameters preset by the central control device, and meeting the requirements of the regulation on the heating curing of the track slab;
D. constant temperature maintenance of track slab
The rail plate is heated up to be cured to meet the requirement for constant temperature curing, water spraying curing is carried out according to the same requirement as the step B, and the central control device acquires the temperatures of corresponding areas in real time according to the environmental temperature sensor 4, the core temperature sensor 17, the surface temperature and humidity sensor 18 and the temperature and humidity sensor 27, and the requirement for constant temperature curing is met through the control of the temperature control device;
E. track slab cooling maintenance
And C, entering a cooling maintenance stage after the constant-temperature maintenance of the track slab is completed, carrying out water spraying maintenance according to the same requirements as those of the step B, closing the steam supply device, and controlling the operation of the air cooling device by the central control device through monitoring the temperature of each sensor so that the temperature meets the cooling maintenance condition requirements in the standard requirements.
F. Maintenance of track slabs
When the automatic door 25 is opened after cooling maintenance is completed, the molds 20 are sequentially conveyed to an external working track along the traveling track 21 by the circulation traction device 19, and the next batch of molds 20 to be maintained sequentially enter a next track slab maintenance procedure.
In the step A, after the mold 20 on one walking track 21 in the steam curing room 1 is full, the automatic door 25 is thoroughly closed to form a curing space, and meanwhile, the mold 20 is pushed onto the adjacent walking track 21 in the steam curing room 1, so that the preparation of track slab curing is completed.
The temperature control method of the constant-temperature water sprinkling device in the step B is that when the water temperature of the water tank 16 is lower than the environmental temperature in the steam curing room 1, the central control device controls the steam supply device to heat the water in the water tank 16; when the water temperature in the water tank 16 is higher than the environmental temperature in the steam curing room 1, the central control device is filled with water and cooled by the self-water-supplementing control device 23.
In the temperature control method in the step C, when the temperature in the sub-cylinder 10 reaches the requirement and the boiler supplies steam to the sub-cylinder through the main steam pipe 11, the central control device controls the opening of the steam control valve group 12, and steam enters the steam raising steam curing room 1 through the auxiliary steam pipe 9, the steam branch pipe 6 and the steam spray holes 7.
The temperature control method in the step D is that when the temperature in the steam curing room 1 needs to be raised, the central control device controls the steam control valve group 12 to be opened, and steam enters the steam curing room 1 to raise the ambient temperature through the steam auxiliary pipe 9, the steam branch pipe 6 and the steam spray hole 7; when the temperature in the steam curing room 1 needs to be reduced, an air cooling device and a constant temperature water supply device are opened, and the central control device controls the fan 8 to input cold air through the air cooling pipeline 3 and the ventilation window 26 so as to realize the temperature reduction in the steam curing room 1; the constant-temperature water spraying device sprays water to the surface of the track plate in the die 20 through the nozzle to realize the cooling of the track plate, and the cooling speed is less than or equal to 15 ℃/h in the cooling process.
In the step E, when the temperatures acquired by the surface temperature and humidity sensor 18 and the environmental temperature and humidity sensor 4 and the temperature and humidity sensor 27 are substantially the same, and the temperature difference between the surface temperature and humidity sensor 18 and the core temperature sensor 17 is not greater than 15 ℃, the temperature reduction maintenance of the track board is completed.
Claims (19)
1. The curing system of the pretensioned prestressed concrete track slab production line comprises a steam curing room (1) capable of accommodating a die (20), wherein a spray head and a spray nozzle which are connected with a steam control output device, a ventilation cooling device and a constant temperature water supply device, a temperature and humidity detection device, a die self-walking device and a temperature and humidity control device which are connected with a central control device are arranged in the steam curing room (1); the automatic steam curing machine is characterized in that a working rail matched with a die (20) is arranged in the steam curing room (1), and automatic doors (25) communicated with a central control device are arranged on the side walls of the two ends of the steam curing room (1); the ground in the steam curing room (1) is provided with a walking track (21) which is matched with the die (20) and a circulation traction device (19) which is used for traction of the die (20), and the walking track (21) is connected with a working track outside the steam curing room (1) to form a die self-walking device; the temperature and humidity detection device comprises a core temperature sensor (17) and a surface layer temperature and humidity sensor (18) which are used for detecting the temperature and humidity of the core and the surface of the track plate in the die (20), and an environment temperature and humidity sensor (4) which is used for detecting the temperature and humidity in the steam curing room (1); the temperature and humidity control device comprises a steam pipeline, a water spraying pipeline and an air cooling device, wherein the steam pipeline is opened in the steam curing room (1) and connected with a peripheral steam supply device;
the steam supply device selects a branch air cylinder (10) with an inlet communicated with the boiler through a main steam pipe (11), an outlet of the branch air cylinder (10) is connected with an auxiliary steam pipe (9), and a steam control valve group (12) is assembled on the auxiliary steam pipe (9);
the steam pipeline comprises steam branch pipes (6) which are arranged at the left side and the right side of the walking track (21) in a longitudinal direction, steam spray holes (7) which are arranged at intervals along the longitudinal direction of the steam branch pipes (6) and correspond to the outer surface of the die (20), and the other ends of the steam branch pipes (6) are communicated with the steam supply device through steam auxiliary pipes (9) and steam control valve groups (12);
the mold (20) is subjected to water spraying curing in the track slab standing curing, heating curing, constant temperature curing and cooling curing procedures, and the track slab heating curing procedures are simultaneously subjected to steam heating curing.
2. Pretensioned prestressed concrete track slab production line maintenance system according to claim 1, characterized in that the opening direction of the steam jet holes (7) is directed in the track direction and forms an angle α1 and α2 with the travelling track, 0 ° < α1 < 90 °,90 ° < α2 < 180 °.
3. Pretensioned prestressed concrete track slab production line maintenance system according to claim 1, characterized in that the opening direction of the steam jet holes (7) forms an angle α1 and α2 with the running track, α1=30°, α2=120°.
4. The pretensioned prestressed concrete track slab production line maintenance system according to claim 1, characterized in that the constant temperature sprinkling device comprises a water tank (16), a constant temperature device arranged in the water tank (16), the constant temperature device comprises a water tank temperature sensor (24) arranged in the water tank (16) and connected with a central control device, and the water tank (16) is communicated with the steam supply device through a pipeline and a control valve.
5. The curing system of pretensioned prestressed concrete track slab production line according to claim 4, wherein said constant temperature sprinkler further comprises a water supplementing pipe with an outlet connected to the water tank (16), and the water supplementing pipe is provided with a self-supplementing control device (23) connected to the central control device.
6. The pretensioned prestressed concrete track slab production line maintenance system according to any one of claims 1 or 4, wherein the nozzle is an atomizer (2), and the atomizer (2) is communicated with a constant-temperature sprinkler through a water spray pipeline, a booster pump (15) and a spray control valve group (14).
7. The pretensioned prestressed concrete track slab production line maintenance system according to claim 6, wherein the water spraying pipeline comprises a water spraying branch pipe (5) and a water spraying auxiliary pipe (13) which are communicated with the atomizing nozzle (2) and the constant-temperature water spraying device at two ends and are connected end to end.
8. The pretensioned prestressed concrete track slab production line maintenance system according to claim 1 or 2, characterized in that the air cooling device comprises a ventilation window (26) arranged at the top of the steam curing room (1), and the ventilation window (26) is communicated with an external fan (8) through an air cooling pipeline (3).
9. The pretensioned prestressed concrete track slab production line maintenance system according to claim 1, characterized in that the temperature and humidity detection means includes a temperature and humidity sensor (27) provided outside the steam curing room (1).
10. The pretensioned prestressed concrete track slab production line maintenance system according to claim 1, characterized in that the surface of the inside of the steam curing house (1) is provided with a drainage ditch (22) communicated with the outside.
11. The pretensioned prestressed concrete track slab production line maintenance system according to claim 1, characterized in that the core temperature sensor (17), the surface layer temperature and humidity sensor (18), the environment temperature and humidity sensor (4) and the temperature and humidity sensor (27) are electrically connected with the central control device in a wired manner through a fixed manner; wherein the core temperature sensor (17) and the surface temperature and humidity sensor (18) are connected through a quick connector.
12. The pretensioned prestressed concrete track slab production line maintenance system according to claim 1, characterized in that the traveling tracks (21) are distributed in parallel at intervals in the steam curing room (1).
13. The pretensioned prestressed concrete track slab production line maintenance system according to any one of claims 1, 10 or 12, wherein said steam curing room (1) is constructed of heat insulating materials.
14. Use of a pretensioned prestressed concrete track slab production line maintenance system according to any of claims 1-13 in pretensioned prestressed concrete track slab maintenance, characterized by comprising the following process steps:
A. track slab maintenance preparation
Drawing the die (20) subjected to pouring and vibrating of the track slab along a walking track (21) by a circulation drawing device (19) into a steam curing room (1), correspondingly opening or closing an automatic door (25) when drawing the die (20) each time, and spraying atomized water after the die (20) enters the steam curing room (1); before spraying, the temperature is monitored and compared in real time through an environment temperature and humidity sensor (4) and a water tank temperature sensor (24), so that the water temperature is ensured to be basically consistent with the temperature in the steam curing room (1);
B. standing maintenance of track slab
When the mold (20) in the travelling rail (21) in the steam curing room (1) is full and the automatic door (25) is thoroughly closed, entering a standing curing stage of the rail plate, starting timing by the central control device, monitoring the temperature in real time through the core temperature sensor (17) and the water tank temperature sensor (24) and comparing the temperature, and controlling the constant-temperature sprinkling device to spray water to the surface of the rail plate in the mold (20) through the nozzle by the central control device to perform standing curing, so that the requirement of the standard on the standing curing of the rail plate is met;
C. track slab heating maintenance
C, heating up and curing are carried out after the track slab is kept still and cured, water spraying curing is carried out according to the same requirements as those of the step B, meanwhile, the central control device carries out environment heating up on the steam curing room (1) by controlling the steam supply device to spray steam through the steam spray holes (7), the environment temperature and humidity sensor (4), the core temperature sensor (17), the surface layer temperature and humidity sensor (18) and the temperature and humidity sensor (27) collect temperatures of corresponding areas in real time, the temperature in the steam curing room (1) is dynamically controlled according to the technological parameters preset by the central control device, and the requirements of the normative heating up and curing of the track slab are met;
D. constant temperature maintenance of track slab
C, carrying out constant-temperature maintenance when the temperature rise maintenance of the track slab reaches the requirement, carrying out water spraying maintenance according to the same requirement as the step B, and acquiring the temperatures of corresponding areas in real time by a central control device according to an environment temperature and humidity sensor (4), a core temperature sensor (17), a surface layer temperature and humidity sensor (18) and a temperature and humidity sensor (27), wherein the constant-temperature maintenance requirement is met through the control of a temperature control device;
E. track slab cooling maintenance
B, entering a cooling maintenance stage after the constant-temperature maintenance of the track slab is completed, carrying out water spraying maintenance according to the same requirements as those of the step B, closing the steam supply device, and controlling the operation of the air cooling device by the central control device through monitoring the temperature of each sensor to ensure that the temperature meets the cooling maintenance condition requirements in the standard requirements;
F. maintenance of track slabs
When the automatic door (25) is opened after cooling maintenance is finished, the molds (20) are sequentially conveyed to an external working track along a traveling track (21) by a circulation traction device (19), and the next batch of molds (20) to be maintained sequentially enter a next track slab maintenance procedure.
15. The use according to claim 14, wherein in said step a, after the mold (20) on one of the traveling rails (21) in the steam curing room (1) is full, the automatic door (25) is completely closed to form a curing space, and the mold (20) is pushed onto the adjacent traveling rail (21) in the steam curing room (1) to complete the preparation for curing the rail plate.
16. The use according to claim 14, characterized in that the temperature control of the constant temperature sprinkler in step B is performed by the central control means controlling the steam supply means to heat the water in the water tank (16) when the water temperature in the water tank (16) is lower than the ambient temperature in the steam curing room (1); when the water temperature in the water tank (16) is higher than the ambient temperature in the steam curing room (1), the central control device is filled with water and cooled by the self-water-supplementing control device (23).
17. The use according to claim 14, wherein in the step C, the temperature control method is that in a state that the temperature in the sub-cylinder (10) reaches the requirement and the boiler supplies steam to the sub-cylinder through the main steam pipe (11), the central control device controls the opening of the steam control valve group (12), and the steam enters the environment temperature in the lifting steam curing room (1) through the auxiliary steam pipe (9), the steam branch pipe (6) and the steam spray hole (7).
18. The use according to claim 14, wherein the temperature control method in the step D is that when the temperature in the steam curing room (1) needs to be raised, the central control device controls the steam control valve group (12) to be opened, and steam enters the steam curing room (1) to raise the ambient temperature through the steam auxiliary pipe (9), the steam branch pipe (6) and the steam spray hole (7); when the temperature in the steam curing room (1) needs to be reduced, an air cooling device and a constant temperature water supply device are opened, and the central control device controls the fan (8) to input cold air through the air cooling pipeline (3) and the ventilation window (26) so as to realize the temperature reduction in the steam curing room (1); the constant-temperature water spraying device sprays water to the surface of the track plate in the die (20) through the nozzle to realize the cooling of the track plate, and the cooling speed is less than or equal to 15 ℃/h in the cooling process.
19. The use according to claim 14, wherein in the step E, the temperature-reducing maintenance of the track board is completed when the temperatures collected by the surface temperature and humidity sensor (18) and the environmental temperature and humidity sensor (4) and the temperature and humidity sensor (27) are substantially the same, and the temperature difference between the surface temperature and humidity sensor (18) and the core temperature sensor (17) is not greater than 15 ℃.
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