CN111890547A - Manufacturing process of elastic supporting block capable of being rapidly stripped - Google Patents
Manufacturing process of elastic supporting block capable of being rapidly stripped Download PDFInfo
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- CN111890547A CN111890547A CN202010728213.1A CN202010728213A CN111890547A CN 111890547 A CN111890547 A CN 111890547A CN 202010728213 A CN202010728213 A CN 202010728213A CN 111890547 A CN111890547 A CN 111890547A
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- die
- elastic supporting
- lifting
- supporting block
- dismantling
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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
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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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/04—Discharging the shaped articles
- B28B13/06—Removing the shaped articles from moulds
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- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
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Abstract
The invention belongs to a manufacturing technology of an elastic supporting block of a ballastless track of a high-speed railway, relates to the manufacturing of the elastic supporting block capable of being subjected to rapid demoulding, and particularly relates to a manufacturing technology of the elastic supporting block capable of being subjected to rapid demoulding. The prefabricated die is transformed, and the top die removing tool and the low die removing tool are manufactured, so that the operation is simple, the processing is convenient, and the manufacturing cost is low; when the system provided by the invention is used for dismantling the elastic supporting blocks which are not demoulded, the dismantling of a plurality of supporting blocks can be completed by lifting once, so that the labor and the time are saved, and the efficiency is extremely high, thereby shortening the whole time for manufacturing the elastic supporting blocks, avoiding the situation that the prefabricated mould can not be circulated frequently when the elastic supporting blocks are manufactured, further accelerating the project progress, and further saving the production cost.
Description
Technical Field
The invention belongs to a manufacturing technology of an elastic supporting block of a ballastless track of a high-speed railway, relates to the manufacturing of an elastic supporting block capable of being subjected to rapid demoulding, and particularly relates to a manufacturing process of an elastic supporting block capable of being subjected to rapid demoulding.
Background
The elastic supporting block is an important component of the ballastless track of the high-speed railway, is mainly used for the railway in the tunnel and mainly plays a role in connection and supporting. The bearing block is formed by sleeving a factory-made pre-embedded iron seat type reinforced concrete precast block on a rubber sleeve shoe with a rubber base plate arranged inside. The existing prefabricated mold for manufacturing the elastic supporting block consists of a top mold of an upper half part and a bottom mold of a lower half part. When the elastic supporting block is manufactured at present, after the elastic supporting block is solidified and hardened in a prefabricated mould, only manual form removal can be carried out, and only one elastic supporting block can be removed in sequence; demolish the die block and then need rely on the built-in fitting to mention its monoblock, and the built-in fitting is small, and the artifical degree of difficulty of just depending on carrying to take the built-in fitting to mention the elastic support piece is also great, leads to the form removal to need to consume a large amount of time. Demolish prefabricated mould and consume a large amount of manpowers and time, inefficiency leads to the process of whole preparation elastic support piece to prolong consuming time, and the unable circumstances of turnover of prefabricated mould often appears moreover, influences the engineering progress.
Disclosure of Invention
The invention aims to solve the technical problems that a large amount of labor and time are consumed and the efficiency is low in the traditional manual membrane detaching process in the process of manufacturing an elastic supporting block, and provides a manufacturing process of the elastic supporting block capable of rapidly demoulding.
The technical means for solving the technical problems of the invention is as follows: a manufacturing process of an elastic supporting block capable of being rapidly stripped comprises the following steps:
the method comprises the following steps: firstly, reforming a prefabricated mould: welding a counterweight part which enables the center of gravity of the top die to move upwards on the upper surface of the top die of the prefabricated die for preparing the elastic supporting block, and respectively welding suspenders in the middles of the front side and the rear side of the top die of the prefabricated die;
step two: manufacturing a top die and dismantling the tool: the top die dismantling tool comprises a first supporting top frame, a plurality of pairs of lifting hooks which are arranged along the vertical direction and correspond to each other in position are welded on the front side and the rear side of the first supporting top frame, the adjacent pairs of lifting hooks are arranged at intervals, and a plurality of first lifting lugs are further welded on the first supporting top frame;
step three: manufacturing a bottom die dismantling tool: the bottom die dismantling tool comprises a second supporting top frame, a plurality of pairs of chains which are arranged along the vertical direction and correspond to each other in position are welded on the front side and the rear side of the second supporting top frame, adjacent pairs of chains are arranged at intervals, clamps which are matched with embedded parts of the elastic bearing blocks are welded at the tail ends of each pair of chains which correspond to each other in position in front and rear, and second lifting lugs are also welded on the second supporting top frame;
step four: grouting and steam curing are carried out on the prefabricated mould, and after the elastic supporting block in the prefabricated mould is molded and hardened, a top mould is removed: hoisting the top die dismantling tool in the second step by using a forklift and a sling rope through the first lifting lug, hoisting the elastic supporting blocks on each pair of lifting hooks by using the lifting rods, inserting a demolding pry bar into a prying hole of the prefabricated die to pry the top die without leaving the ground, separating the top die from the elastic supporting blocks, continuously hoisting the top die slowly, and completing the top die dismantling; the top die of the prefabricated die is additionally provided with the counterweight, so that the top die can be automatically turned over in the process of continuously lifting;
step five: and (3) dismantling the bottom die: lifting the bottom die dismantling tool in the third step by using a forklift and a sling through a second lifting lug, respectively clamping a plurality of clamps of the bottom die dismantling tool in embedded parts on a plurality of elastic supporting blocks, tensioning the elastic supporting blocks upwards at the moment, lightly knocking the side edges of the bottom die from the front side, the rear side and the left side and the right side of the bottom die by using a hammer, loosening the bottom die and the elastic supporting blocks, continuously lifting the bottom die dismantling tool upwards, lifting the elastic supporting blocks along with the bottom die dismantling tool, and finishing the dismantling of the bottom die;
step six: and D, keeping the interior of the top die in the fourth step upwards, enabling the top die to fall to the ground, spraying a release agent in the top die, then installing an embedded part, then reassembling the top die and the bottom die, and then repeating the fourth step to the sixth step to manufacture the elastic supporting block of the next round.
The system can finish the dismantling of a plurality of elastic supporting blocks at the same time, and the dismantling process is labor-saving and time-saving. The center of gravity of the top die is moved upwards by the aid of the balance weight piece, the top die can be automatically turned in the process of lifting the top die, the process of manually turning the top die is omitted, and the design is ingenious.
The invention has the beneficial effects that: the operation is convenient, the mastering is easy, the operation is simple when the prefabricated die is reformed and the top die removing tool and the low die removing tool are manufactured, the processing is convenient, and the manufacturing cost is lower; when the system provided by the invention is used for dismantling the elastic supporting blocks which are not demoulded, the dismantling of a plurality of supporting blocks can be completed by lifting once, so that the labor is saved, the time is saved, and the efficiency is extremely high, thereby shortening the whole time for manufacturing the elastic supporting blocks, avoiding the situation that the prefabricated mould can not be circulated frequently when the elastic supporting blocks are manufactured, further accelerating the project progress, further saving the production cost, and having higher practicability and economic benefit.
Drawings
FIG. 1 is a process flow diagram of a process for manufacturing an elastic support block capable of being rapidly stripped according to the present invention.
Fig. 2 is a front view of the top die removing tool according to the present invention.
Fig. 3 is a top view of the top die removing tool according to the present invention.
Fig. 4 is a left side view of the top die removing tool according to the present invention.
Fig. 5 is a front view of the bottom die removing tool according to the present invention.
Fig. 6 is a top view of the bottom die removing tool according to the present invention.
Fig. 7 is a left side view of the bottom die removing tool according to the present invention.
Fig. 8 is a schematic view of the top die removing tool for hoisting the prefabricated die.
Fig. 9 is a schematic view of the top cover of the prefabricated mold hoisted by the top mold dismantling tool of the invention.
Fig. 10 is a schematic diagram of hoisting an embedded part when a bottom die remover mounts and removes the bottom die.
In the figure: 1-prefabricating a mould; 2-a counterweight; 3-a suspender; 4-a first supporting top frame; 5-a hook; 6-a first lifting lug; 7-a second supporting top frame; 8-a chain; 9-a fixture; 10-a second lifting lug.
Detailed Description
Referring to fig. 1 to 10, a process for manufacturing a resilient support block capable of being rapidly stripped according to the present invention will be described in detail.
A process for manufacturing an elastic supporting block capable of being rapidly stripped, as shown in fig. 1, comprising the following steps:
the method comprises the following steps: firstly, the prefabricated mould 1 is reformed: welding a counterweight 2 which enables the center of gravity of a top die to move upwards on the upper surface of the top die of a prefabricated die 1 for preparing an elastic supporting block, and respectively welding suspenders 3 in the middles of the front side and the rear side of the top die of the prefabricated die 1; wherein a top-mould view of the prefabricated mould 1 is shown in figures 8 and 9;
step two: manufacturing a top die and dismantling the tool: the top die dismantling tool comprises a first supporting top frame 4, a plurality of pairs of lifting hooks 5 which are arranged along the vertical direction and correspond to each other in position are welded on the front side and the rear side of the first supporting top frame 4, the adjacent pairs of lifting hooks 5 are arranged at intervals, and a plurality of first lifting lugs 6 are further welded on the top frame of the first supporting top frame 4; as shown in particular in fig. 2, 3 and 4;
step three: manufacturing a bottom die dismantling tool: the bottom die dismantling tool comprises a second supporting top frame 7, a plurality of pairs of chains 8 which are arranged along the vertical direction and correspond in position are welded on the front side and the rear side of the second supporting top frame 7, adjacent pairs of chains 8 are arranged at intervals, clamps 9 which are matched with embedded parts of elastic bearing blocks are welded at the tail ends of each pair of chains 8 corresponding to the front side and the rear side of the position, and second lifting lugs 10 are also welded on the second supporting top frame 7; as shown in particular in fig. 5, 6 and 7;
step four: grouting and steam curing are carried out on the prefabricated mould 1, and after the elastic supporting block in the prefabricated mould 1 is molded and hardened, a top mould is removed: hoisting the top die dismantling tool in the second step by using a forklift and a sling through the first lifting lug 6, hoisting the elastic supporting blocks on each pair of lifting hooks 5 by using the lifting rods 3, inserting a demolding pry bar into a prying hole of the prefabricated die 1 to pry the top die without leaving the ground, separating the top die from the elastic supporting blocks, continuously and slowly hoisting the top die, and completing the top die dismantling; the top die of the prefabricated die 1 is automatically turned over in the process of continuously lifting due to the addition of the counterweight 2; as shown in fig. 8 and 9;
step five: and (3) dismantling the bottom die: hoisting a bottom die dismantling tool in the third step by using a forklift and a sling through a second lifting lug 10, respectively clamping a plurality of clamping tools 9 of the bottom die dismantling tool in embedded parts on a plurality of elastic supporting blocks, tensioning the elastic supporting blocks upwards at the moment, lightly knocking the side edges of the bottom die from the front side, the rear side and the left side and the right side of the bottom die by using a hammer, loosening the bottom die and the elastic supporting blocks, continuously lifting the bottom die dismantling tool upwards, lifting the elastic supporting blocks along with the bottom die dismantling tool, and finishing the dismantling of the bottom die; as shown in fig. 10;
step six: and D, keeping the interior of the top die in the fourth step upwards, enabling the top die to fall to the ground, spraying a release agent in the top die, then installing an embedded part, then reassembling the top die and the bottom die, and then repeating the fourth step to the sixth step to manufacture the elastic supporting block of the next round.
Further, as a specific embodiment of the manufacturing process of the elastic supporting block capable of being rapidly stripped, in the second step, the first supporting top frame 4 of the top mold removing tool is a grid-shaped structure frame body formed by welding square steel pipes, and two long sides of the grid-shaped structure frame body are respectively the front side and the rear side of the first supporting top frame 4. The size of square steel is 120 mm x 5mm, and the first support roof 4 length that welds becomes is 1600 mm, and is wide for 650 mm, and first support roof 4 is mesh font structure support body, and the connecting square pipe in the middle of it can make first support roof 4 stable in structure, specifically as shown in fig. 3.
Further, as a specific implementation manner of the manufacturing process of the elastic supporting block capable of rapidly demoulding, the lifting hook 5 of the top mould dismounting tool in the second step is formed by bending a steel bar. HRB400 hot-rolled ribbed steel bars with the diameter of the steel bar phi 20, and the length of a lifting hook 5 is 85 mm. The distance between two adjacent hooks 5 is 320mm, as shown in fig. 2 and 4.
Further, as a specific embodiment of the manufacturing process of the elastic supporting block capable of rapidly demoulding, in the second step, a pair of first lifting lugs 6 are respectively welded to the front portion and the rear portion of the first supporting top frame 4 of the top die removing tool, and the first lifting lugs 6 are correspondingly welded to the front side and the rear side of the first supporting top frame 4 in pairs. Specifically, a pair of first lifting lugs 6 are welded to the front part and the rear part of the first supporting top frame 4 respectively. This is to keep the first supporting roof rack 4 balanced when lifting the top mould to remove the tooling, as shown in fig. 2 and 4.
Further, as a specific embodiment of the manufacturing process of the elastic support block capable of rapidly demoulding, the second supporting top frame 7 of the bottom mould dismantling tool in the third step is made of an i-shaped steel section, and the chains 8 are respectively welded to two side walls of the i-shaped steel. The I-steel section uses 18# I-steel and has the length of 1600 mm. The distance between two adjacent chains 8 on the second supporting top frame 7 is 320mm, as shown in fig. 7.
Further, as a specific embodiment of the manufacturing process of the elastic support block capable of rapidly demoulding, the fixture 9 of the bottom mould dismantling tool in the third step is made of an angle steel section, the structure of the angle steel section is matched with the internal structure of the embedded part, the concave surface of the angle steel section is arranged downwards, and the tail end of the chain 8 is welded to the top end of the right angle of the angle steel. The inner sides of the embedded parts are provided with symmetrical grooves, so that the angle steel can be inserted between the symmetrical grooves, two side walls of the angle steel are completely clamped with the grooves, and a lifting supporting point for the elastic supporting block is formed, and the structure is particularly shown in figure 5.
Further, as a specific implementation manner of the manufacturing process of the elastic supporting block capable of rapidly demoulding, the fixture 9 of the bottom mould dismantling tool in the third step is made of a steel plate, and the width of the steel plate is matched with the internal structure of the embedded part. The inner sides of the embedded parts are provided with symmetrical grooves, so that the steel plates can be inserted between the symmetrical grooves to form lifting supporting points for the elastic supporting blocks.
Further, as a specific embodiment of the manufacturing process of the elastic support block capable of rapidly demoulding, in the third step, a second lifting lug 10 of the bottom mould removing tool is welded on the top surface of the second supporting top frame 7, and two second lifting lugs 10 are welded and located at the head and the tail of the second supporting top frame 7 respectively. The second lifting lugs 10 are welded at the head part and the tail part of the second supporting top frame 7 respectively. This is to keep the second supporting top frame 7 balanced when lifting the bottom die to remove the tool, as shown in fig. 6.
Further, as a specific embodiment of the manufacturing process of the elastic support block capable of rapidly demoulding, the number of the hooks 5 on the first supporting top frame 4 is five, and the number of the chains 8 on the second supporting top frame 7 is five. In this way, the mold stripping can be simultaneously completed on the five elastic supporting blocks, and the mold stripping efficiency is improved, as shown in fig. 2, fig. 5, fig. 6, fig. 8, fig. 9 and fig. 10.
Further, as a specific implementation manner of the manufacturing process of the elastic support block capable of rapidly demoulding, the weight part 2 welded on the upper surface of the top mould is a rectangular solid block or a support leg structure. The weight part 2 can not only enable the center of gravity of the top die to move upwards, after the top die is turned, the weight part 2 can also serve as a supporting leg to support the top die, and the next operation of the top die, such as installation of an embedded part and spraying of a release agent, is convenient, and is specifically shown in fig. 8 and 9.
After the process is adopted, on the premise of not increasing the input of manpower and material resources, the time of each construction cycle is greatly shortened, one working cycle is increased to two working cycles each day, the yield is increased to 1000 blocks/day from the previous 500 blocks/day, the site construction is met, the completion of all production tasks is 13 days ahead of the predicted construction period, and the labor cost, the mechanical cost input and the like are saved by about 15 ten thousand yuan.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (10)
1. A manufacturing process of an elastic supporting block capable of being rapidly stripped is characterized by comprising the following steps:
the method comprises the following steps: firstly, the prefabricated mould (1) is reformed: welding a counterweight (2) which enables the center of gravity of a top die to move upwards on the upper surface of the top die of a prefabricated die (1) for preparing an elastic supporting block, and respectively welding suspenders (3) in the middles of the front side and the rear side of the top die of the prefabricated die (1);
step two: manufacturing a top die and dismantling the tool: the top die dismantling tool comprises a first supporting top frame (4), a plurality of pairs of lifting hooks (5) which are arranged along the vertical direction and correspond to each other in position are welded on the front side and the rear side of the first supporting top frame (4), the adjacent pairs of lifting hooks (5) are arranged at intervals, and a plurality of first lifting lugs (6) are welded on the top frame of the first supporting top frame (4);
step three: manufacturing a bottom die dismantling tool: the bottom die dismantling tool comprises a second supporting top frame (7), a plurality of pairs of chains (8) which are arranged along the vertical direction and correspond to each other in position are welded on the front side and the rear side of the second supporting top frame (7), adjacent pairs of chains (8) are arranged at intervals, clamps (9) which are matched with embedded parts of elastic bearing blocks are welded on the tail ends of each pair of chains (8) which correspond to each other in position in the front and rear directions, and second lifting lugs (10) are also welded on the second supporting top frame (7);
step four: grouting and steam curing are carried out on the prefabricated mould (1), and after the elastic supporting block in the prefabricated mould (1) is molded and hardened, a top mould is removed: lifting the top die dismantling tool in the second step by using a forklift and a sling through a first lifting lug (6), lifting an elastic supporting block on each pair of lifting hooks (5) through a lifting rod (3), inserting the elastic supporting block which is not dismantled into the ground without leaving the ground, prying the top die by using a demolding prying bar, separating the top die from the elastic supporting block, continuously and slowly lifting the top die, and completing the dismantling of the top die; the top die of the prefabricated die (1) is automatically turned over in the process of continuously lifting due to the addition of the counterweight (2);
step five: and (3) dismantling the bottom die: hoisting a bottom die dismantling tool in the third step by using a forklift and a sling through a second lifting lug (10), respectively clamping a plurality of clamping tools (9) of the bottom die dismantling tool in embedded parts on a plurality of elastic supporting blocks, tensioning the elastic supporting blocks upwards at the moment, lightly knocking the side edges of the bottom die from the front side, the rear side and the left side and the right side of the bottom die by using a hammer, loosening the bottom die and the elastic supporting blocks, continuously lifting the bottom die dismantling tool upwards, lifting the elastic supporting blocks along with the bottom die dismantling tool, and finishing the dismantling of the bottom die;
step six: and D, keeping the interior of the top die in the fourth step upwards, enabling the top die to fall to the ground, spraying a release agent in the top die, then installing an embedded part, then reassembling the top die and the bottom die, and then repeating the fourth step to the sixth step to manufacture the elastic supporting block of the next round.
2. The manufacturing process of the elastic supporting block capable of rapidly demoulding according to the claim 1, wherein the first supporting top frame (4) of the top mould removing tool in the second step is a grid-shaped structure frame body formed by welding square steel pipes, and two long sides of the grid-shaped structure frame body are respectively the front side and the rear side of the first supporting top frame (4).
3. The process for manufacturing an elastic supporting block capable of being rapidly stripped according to claim 1, wherein in the second step, the lifting hook (5) of the top die removing tool is formed by bending a steel bar.
4. The manufacturing process of the elastic supporting block capable of rapidly demoulding according to the claim 1, characterized in that in the second step, a pair of first lifting lugs (6) are respectively welded at the front and rear parts of the first supporting top frame (4) of the top mould dismantling tool, and the first lifting lugs (6) are correspondingly welded to the front and rear sides of the first supporting top frame (4) in pairs.
5. The process for manufacturing an elastic supporting block capable of rapidly demoulding according to claim 1, wherein the second supporting top frame (7) of the bottom mould dismantling tool in the third step is made of an i-shaped steel section, and the chains (8) are respectively welded to two side walls of the i-shaped steel.
6. The process for manufacturing the elastic supporting block capable of rapidly demoulding according to the claim 1, characterized in that the fixture (9) of the bottom die dismantling tool in the third step is made of an angle steel section, the structure of the angle steel section is matched with the internal structure of the embedded part, the concave surface of the angle steel section is arranged downwards, and the tail end of the chain (8) is welded to the top end of the right angle of the angle steel.
7. The process for manufacturing an elastic supporting block capable of being rapidly stripped according to claim 1, wherein the fixture (9) of the bottom die removing tool in the third step is made of a steel plate, and the width of the steel plate is matched with the internal structure of the embedded part.
8. The process for manufacturing an elastic supporting block capable of rapidly demoulding according to claim 1, wherein the second lifting lug (10) of the bottom mould dismantling tool in the third step is welded on the top surface of the second supporting top frame (7), and the second lifting lug (10) is welded with two lifting lugs which are respectively positioned at the head part and the tail part of the second supporting top frame (7).
9. A process for making an elastic support block capable of being rapidly stripped according to any one of claims 1 to 8, characterized in that the number of the hooks (5) on the first support top frame (4) is five, and the number of the chains (8) on the second support top frame (7) is five.
10. A process for making a resilient support block with a quick release capability according to claim 9, wherein in step one, the weight member (2) welded to the upper surface of the top mold is a rectangular solid block or a support leg structure.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN114986663A (en) * | 2022-06-10 | 2022-09-02 | 玛戈隆特骨瓷（上海）有限公司 | Slip casting device for ceramic manufacturing and process thereof |
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