CN112721001B - Complete equipment and system for production and detection of polyurethane track bed blocks and use method - Google Patents

Abstract

The invention discloses a complete set of equipment and a system for producing and detecting a polyurethane track bed block and a using method thereof, wherein the complete set of equipment comprises a mould matched with a sleeper, a locking cover for sealing the mould and a foaming machine for foaming polyurethane; the mould further comprises a tap assembly, and the tap assembly is used for pressing the interior of the mould and providing vibration. The invention provides complete equipment, a system and a using method for production and detection of a polyurethane track bed block, which are used for solving the problem that the polyurethane track bed block is difficult to stably prefabricate in the prior art and achieving the purposes of stably prefabricating the polyurethane track bed block and detecting whether a product is qualified or not.

Description

Complete equipment and system for production and detection of polyurethane track bed blocks and use method

Technical Field

The invention relates to the field of rail transit, in particular to complete equipment and a complete system for producing and detecting a polyurethane track bed block and a using method of the complete system.

Background

The ballast bed is an important component of the track and is the foundation of the track frame. The sleeper-supporting device comprises a sleeper and ballast stones, and is mainly used for supporting the sleeper, uniformly transmitting the huge pressure on the upper part of the sleeper to a roadbed, fixing the position of the sleeper, preventing the sleeper from longitudinally or transversely moving, greatly reducing the deformation of a roadbed, simultaneously relaxing the impact of a locomotive wheel on a steel rail, and facilitating drainage.

The traditional track bed is divided into a common ballast track bed, an asphalt track bed and a concrete integral track bed. The conventional ballast bed is usually formed by piling hard crushed stones with certain particle size, grading and strength, and graded pebbles or coarse sand can be used on a secondary line. The asphalt track bed is a structural form added with emulsified asphalt or asphalt mortar for improving the dispersion characteristics of the common stone ballast track bed. The whole ballast bed is usually of a cast-in-place reinforced concrete structure and is usually used in a tunnel or on a bridge which is not easy to deform.

In recent years, a polyurethane curing ballast bed filled with polyurethane foam has appeared, and has excellent characteristics of bearing and damping capacity. The polyurethane curing ballast bed is a novel track structure between a ballast track and a ballastless track, and has good elasticity of the ballast track and stability and maintenance-free performance of the ballastless track structure. In the prior art, a polyurethane curing ballast bed mostly adopts a cast-in-place forming technology, the outdoor operation is greatly influenced by climate, the quality of the polyurethane curing ballast bed is not easy to control, the field construction difficulty is high, equipment needs to be installed and debugged on the field, and the equipment can move along with the track construction continuously, and as various advantages of the polyurethane curing ballast bed, such as maintenance-free performance, low noise, good stability and the like, how to better popularize the polyurethane curing ballast bed technology to become one of core resistances for restricting the application and development of the technology, the applicant of the present application proposes a solution idea of a prefabricated polyurethane ballast bed block. Based on this, the applicant invented the polyurethane roadbed block production detection complete equipment and system.

Disclosure of Invention

The invention provides complete equipment, a system and a using method for production and detection of a polyurethane track bed block, which are used for solving the problem that the polyurethane track bed block is difficult to stably prefabricate in the prior art and achieving the purposes of stably prefabricating the polyurethane track bed block and detecting whether a product is qualified or not.

The invention is realized by the following technical scheme:

a complete set of equipment for producing and detecting a polyurethane track bed block comprises a mould matched with a sleeper, a locking cover for sealing the mould and a foaming machine for foaming polyurethane; the mould further comprises a tap assembly, and the tap assembly is used for pressing the interior of the mould and providing vibration.

The invention aims at solving the problem that the polyurethane track bed block is difficult to be stably prefabricated in the prior art, and firstly provides a complete set of equipment for producing and detecting the polyurethane track bed block. The inventor of the present case discovers in a large amount of research processes, the product quality of polyurethane track bed piece is good and bad, have very big relevance with the dense degree of gaza stone, if it is not enough to lead to the dense degree of gaza stone, lead to the product to be compressed when the deformation volume is too big and then unsatisfied track traffic standard requirement easily, this application sets up the jolt subassembly for this reason, after filling gaza stone in to the mould, pressurize and exert vibration simultaneously to the mould inside by the jolt subassembly, make through vibration that gaza stone is closely knit each other and compress tightly it through exerting pressure, make the intimate contact between gaza stone and the sleeper simultaneously, can obtain the wholeness better like this, the better polyurethane track bed piece product of dense degree.

And, the plain bumper subassembly in this application can independently exert pressure under the prerequisite that does not provide the vibration, consequently after the product curing shaping, remove the product to plain bumper subassembly below once more, exert detection pressure through the plain bumper subassembly, detect the product deformation volume this moment, can judge whether this product satisfies the standard requirement, and then accomplish the detection whether qualified to the product. The foaming machine for polyurethane foaming in the present application can be realized by using the prior art, and is not described herein in detail. The state of locating when laying on the railway roadbed with the sleeper is positive, and the sleeper can place in the mould forward in this application, also can invert and place in the mould, and what need notice, no matter the sleeper is placed forward or is inverted and place, all belongs to within the protection scope of this application, corresponding mould shape and sleeper place the condition support can: considering the structural requirement of the polyurethane track bed block, if the sleeper is placed in the mold in the forward direction, a layer of boulders needs to be laid in the mold firstly, then compaction is carried out, then the sleeper is placed, the rest boulders are filled, and the compaction is carried out again; if the sleeper is placed in the mold in an inverted mode, the sleeper is placed in the mold, at the moment, part of the sleeper needs to penetrate out of the bottom of the mold, and then the sleeper is filled in the mold, at the moment, the height of the sleeper needs to be higher than that of the top of the sleeper, and the sleeper is buried in the mold through the pebble blocks. The using process of the complete equipment can be briefly described as follows: firstly, a sleeper and stones are filled in a mould, then the mould is integrally moved to the position of a vibration assembly, vibration and downward compaction are carried out in the mould through the vibration assembly until the density of the stones in the mould meets the requirement (whether the requirement is met can be judged through the downward pressing stroke of the vibration assembly or the displacement of the vibration assembly under the application of set pressure), then polyurethane raw materials are poured into the mould through a foaming machine, the polyurethane raw materials after high-pressure mixing are injected into the mould, the polyurethane raw materials enter the gaps between the ballast stones and the gaps between the ballast stones and the sleeper are fully filled, the mould is sealed through a locking cover immediately after the injection of the raw materials is finished, the polyurethane raw materials are fully foamed until the polyurethane raw materials are cured, then the locking cover is opened, demoulding and the product is taken out, a polyurethane ballast block product is obtained, the product is pressurized through the vibration assembly again, and the shape variation under the set pressure is detected, thereby judging whether the product meets the requirements.

In addition, because the curing time of the polyurethane is long, when the polyurethane curing mold is used, the mold waiting for the curing process can be integrally moved away, and other molds are used for producing the next product, so that batch production can be realized through one set of equipment, and only more molds need to be configured for alternate use.

In the application, the polyurethane raw material can be poured manually or mechanically automatically, and the mechanical automatic pouring which is more uniform in pouring and more accurate in pouring amount and pouring path control is preferred.

Further, the device also comprises a rail, wherein the mould is detachably connected on the rail and can move along the rail; the tap assembly is fixedly connected to the track. One reason that the prefabricated polyurethane ballast bed block in the prior art is difficult to popularize is that the weight of a single block is large, the single block needs to be transported to each track operation site for a long distance after being prefabricated in a factory, and the transportation cost is extremely high; for this scheme passes through the track and forms the production line, can be comparatively convenient with mould, foaming machine, have the track of jolt ramming subassembly transition jointly and remove to carrying out interim installation in the near factory building of corresponding operation scene, equipment can carry out nimble removal along with the change in construction project or operation place, consequently can satisfy the demand of production nearby, is showing the cost of transportation that reduces prefabricated product, and then is favorable to the wide use of prefabricated polyurethane roadbed piece.

Furthermore, the locking device also comprises a mechanical arm matched with the locking cover, and the mechanical arm is used for taking and placing the locking cover. The specific structure of the robot arm is not limited herein, as long as the locking cover can be covered on the mold and removed from the mold. The power source of the mechanical arm can be pneumatic, hydraulic or electric, and the technical personnel in the field can carry out adaptive setting according to actual conditions.

Furthermore, the locking cover comprises a fixed plate, a floating compression plate and a bracket; the floating compression plate is movably matched below the fixed plate through the guide post, and a compression air bag is arranged between the fixed plate and the floating compression plate; the support is connected above the fixing plate, a locking hook used for hooking the die is arranged on the support, and the mechanical arm is matched with the support. According to the scheme, after the locking cover covers the mold, the compression air bag is inflated, the compression air bag expands, the floating compression plate is pushed to move downwards along the guide column, and then compression force is continuously applied to stones in the mold by the floating compression plate, so that the stability of the foaming process is remarkably improved, and the product forming effect is ensured. The bracket on the fixing plate is matched with the mechanical arm, so that the locking cover can be conveniently taken and placed through the mechanical arm; the locking hook is matched with the die and used for realizing connection and locking with the die.

Further, the die comprises a first bearing body and two die boxes positioned on the first bearing body, wherein a first notch used for exposing the sleeper is formed in the bottom of each die box, a second notch is formed in one side, opposite to each other, of each die box, and the bottom of each second notch is matched with the inverted sleeper in shape; the sleeper is filled with the first gap and the baffle is used for plugging the second gap when the sleeper is placed in the two mould boxes; the width of the mould box is gradually reduced from top to bottom. This scheme specifically prescribes a limit to the mould shape, and polyurethane railway roadbed piece is formed by sleeper both sides cladding polyurethane zeza material, consequently sets up two mould casees and holds the sleeper both ends respectively, and regional sleeper is unsettled between two mould casees or bear through all the other parts can. The inventor finds that the defective rate is high if the sleeper is placed in the forward direction for production in a large number of experiments and research processes, and the reason for the defective rate is that the raw materials are deposited under the action of gravity and have high bottom density when being foamed, and the contact position of the raw materials and the sleeper is located on the upper portion of the raw materials, so that the contact effect between the foamed polyurethane and the sleeper is poor, and even the foamed polyurethane is easy to fall off. Therefore, as another invention point of the application, a special mold is arranged for placing the sleeper in an inverted manner, and the contact position of the sleeper and the raw materials is located at the lower part of the raw materials, so that the characteristic of natural deposition of the raw materials can be utilized to realize the full contact between the sleeper and the raw materials with higher density, meanwhile, the section of the inverted sleeper is in an inverted trapezoid shape, the raw materials below the inclined planes at two sides are molded upwards after foaming and can be fully connected with the side surface of the sleeper naturally, therefore, the scheme adopts a mode of inverted production of the sleeper through the special mold, compared with the mode of forward placement of the sleeper for production, the contact effect between the sleeper and the raw materials can be obviously improved, the contact effect between the sleeper and the polyurethane blocks in the finished product is further improved, the falling risk is reduced, the defective rate is reduced. In addition, the sleeper is placed in an inverted mode, only one compaction is needed, and compared with a mode that two times of compaction are needed when the sleeper is placed in a forward direction, the production efficiency and the compactness of the cobbles are obviously improved. In addition, this application is because the sleeper is invert and is carried out production, so make the width of moulding box from top to bottom reduce gradually, so not only the later stage drawing of patterns of being convenient for, can also accomplish when placing the product forward in production, polyurethane railway roadbed piece is regular trapezium structure, can show the stability that increases the sleeper, and it has more stable better result of use to compare to invert the trapezoidal sleeper obviously among the prior art.

Further, still include with the first breach assorted climbing mechanism of two mould bottom, with climbing mechanism assorted stop gear, climbing mechanism is used for jacking sleeper, stop gear is used for the mould case to go upward when jacking sleeper. The jacking mechanism is used for jacking the sleeper from the bottom after the product is cured to demould, so that the jacking mechanism needs to be matched with the first gaps at the bottoms of the two mould boxes, and the jacking force of the jacking mechanism can act on the inverted sleeper extending out of the first gaps conveniently. In order to avoid jacking the mould box by the jacking mechanism, the limiting mechanism is arranged, and the mould box is limited to move upwards by the limiting mechanism in the demoulding process. The limiting mechanism in the scheme can be realized in any mode, such as pressing the mold box, pulling the mold box or locking the mold box from the outside.

Further, the jolt ramming subassembly is including holding the mounting bracket of mould, the shaking table that is located the mounting bracket, be used for to the shaking table lift hydro-cylinder of exerting pressure downwards, be used for driving the vibrating motor of shaking table vibration, be used for carrying out the direction subassembly to the lift of shaking table. The die can move into the mounting frame, and the lifting oil cylinder drives the vibrating table to move downwards so as to apply pressure to the die below; simultaneously vibrating motor can drive the shaking table and vibrate, consequently in the real-time that needs shake, start vibrating motor can pass through the shaking table and transmit the mould of vibration below. The scheme realizes the integration of vibration and compaction functions, and is favorable for ensuring the sufficient compaction of the stones. In addition, the lifting of the vibration table is guided by the guide assembly, so that the vibration table is ensured to stably ascend and descend, the shaking is avoided, and the stable pressure application in the vibration process is fully ensured; meanwhile, the guide assembly can also absorb the transverse vibration energy of the vibration table, so that the vibration table can vibrate up and down, and high-efficiency compaction of the zeza stones is ensured. The guide assembly in the scheme can be any existing guide device such as a guide post and a guide rail.

The product detection mechanism comprises a second bearing body and a containing device positioned on the second bearing body, and the containing device is used for containing the polyurethane track bed block placed in the forward direction; the detection assembly comprises a positioning piece and a mounting plate which are distributed vertically, the positioning piece is connected with the mounting plate through a connecting rod, and a plurality of displacement detection devices are arranged on the positioning piece; the displacement detection device is used for detecting the downward displacement of the pressure transmission piece and can be realized by using a dial indicator or a dial indicator and the like. The detection to polyurethane railway roadbed piece needs the pressurized state when simulating normal use, consequently can place polyurethane railway roadbed piece product forward in product detection mechanism in this scheme, installs detecting element on product detection mechanism again, later removes product detection mechanism to the plain bumper subassembly below, exerts pressure through the plain bumper subassembly, detects the deformation volume of polyurethane railway roadbed piece under the assigned pressure by detecting element, obtains the testing result. In addition, the detection assembly can be detachably connected with the mold, and the detection assembly is mounted on the mold after the catamite is filled and vibrated, the vibration assembly presses downwards, and the compaction degree of the catamite is detected according to the deformation quantity obtained by the detection assembly. The mounting plate of the detection assembly is detachably connected with the product detection mechanism and the die, the positioning piece is used for contacting with the detected surface, and deformation quantity is accurately detected through a plurality of displacement detection devices arranged on the positioning piece; the connecting rod plays a role in height compensation, and a telescopic rod or a structure with adjustable rest length can be preferably used. The inevitable and setting element direct or indirect fixed connection of pressure conduction spare plays the high compensation effect that detects the position, and the detection pressure effect that the compaction subassembly was exerted downwards simultaneously reaches the piece at pressure on, reaches the piece through pressure and transmits to the setting element, and the rethread setting element transmits to the product that is detected or builds on the stone, has avoided the direct contact of compaction subassembly and product or has besieged a stone, has played the effect of isolation protection.

A complete system for production and detection of polyurethane track bed blocks comprises a pretreatment station, a compaction station and a material injection station; the device also comprises a mould and a product detection mechanism which can move among the pretreatment station, the compaction station and the material injection station, and a locking cover for sealing the mould;

the compaction station is provided with a compaction assembly for applying pressure to the interior of the die and providing vibration;

and the material injection station is provided with a foaming machine for foaming polyurethane.

This system adopts the mode of production line, for the prefabrication of polyurethane roadbed piece provides preliminary treatment station, jolt ramming station, notes material station, and mould, product detection mechanism homoenergetic enough make a round trip to move between each station, and then accomplish whole production process.

The system comprises the following production detection methods:

s1, placing the mold on a pretreatment station, spraying a release agent on the inner wall of the mold, placing the sleeper in the mold in an inverted manner, and sealing the contact part of the mold and the sleeper through a sealing device; the sealing device can be a rubber pad, a rubber ring or other existing mechanical sealing modes to avoid the leakage of the poured raw materials from the bottom of the mold;

s2, filling the gravel into the mold to a set height, and enabling the height of the gravel to reach the set height;

s3, moving the mold to a compaction station, and pressing the stones and the sleepers in the mold downwards through a compaction assembly along with vibration;

s4, moving the die to a material injection station, and injecting a polyurethane foaming raw material into the die through a foaming machine; after the injection is finished, the locking cover is covered for locking, the pressing air bag in the locking cover is inflated, and the pressing air bag continuously maintains pressure and applies pressure to the zaar stones in the mold through the floating pressing plate;

s5, moving the mold back to a pretreatment station, and waiting for curing at the pretreatment station, or moving the mold integrally away to wait for curing;

s6, after curing, taking down the locking cover, pressing the molded polyurethane track bed block upwards to eject out, completing demolding, taking out the demolded polyurethane track bed block, and placing the demolded polyurethane track bed block on a product detection mechanism in the forward direction;

s7, mounting a detection component on the product detection mechanism, wherein the detection component is used for detecting the displacement of the sleeper under the rated pressure; remove product detection mechanism to the tap station, exert the set pressure to the sleeper through the tap subassembly downwards, detect the deformation volume of sleeper: if the deformation amount of the sleeper is smaller than the standard threshold value, the product is qualified; otherwise, the product is unqualified.

Compared with the prior art, the invention has the following advantages and beneficial effects:

1. the complete equipment, the system and the use method for producing and detecting the polyurethane track bed block provided by the invention provide the idea of the polyurethane track bed block, solve the problem that the polyurethane track bed block is difficult to stably prefabricate in the prior art, can stably prefabricate the polyurethane track bed block, and effectively avoid a plurality of construction difficulties of a field pouring mode.

2. According to the complete equipment, the system and the using method for producing and detecting the polyurethane ballast block, the vibration and compaction assembly is arranged, after the ballast stones are filled in the mold, the vibration and compaction assembly applies pressure to the interior of the mold and simultaneously applies vibration, the ballast stones are compacted mutually through the vibration and are compacted through the pressure application, meanwhile, the ballast stones are tightly contacted with the sleeper, and the polyurethane ballast block product with better integrity and better compaction degree can be obtained.

3. According to the complete equipment and the system for producing and detecting the polyurethane track bed block and the using method thereof, detection pressure can be applied through the vibrating compaction component, so that the deformation quantity of a product can be detected, and whether the product meets the standard requirement or not can be judged.

4. The invention relates to a complete set of equipment, a system and a using method for producing and detecting a polyurethane ballast block.A special die is arranged for placing a sleeper in an inverted manner, and the contact position of the sleeper and a raw material is positioned at the lower part of the raw material, so that the full contact between the sleeper and the raw material with higher density can be realized by utilizing the characteristic of natural deposition of the raw material.

5. According to the complete equipment, the system and the using method for production and detection of the polyurethane track bed blocks, the production mode that the sleepers are placed in an inverted mode only needs one-time compaction, and compared with the mode that two times of compaction are needed when the sleepers are placed in a forward direction, the production efficiency and the compactness of the ballast are obviously improved; meanwhile, the finished sleeper product is of a regular trapezoidal structure, the stability of the sleeper is obviously improved, and the sleeper has a more stable using effect obviously compared with an inverted trapezoidal sleeper in the prior art.

6. The complete equipment, the system and the using method for production and detection of the polyurethane track bed block have the advantages that the equipment is compact in design, transportation can be realized by one large truck, the equipment can be conveniently transferred to a factory building nearby an operation site for temporary installation, and the equipment can flexibly move along with the change of construction projects or operation sites, so that the requirement on nearby production can be met, the transportation cost of prefabricated products is remarkably reduced, and the popularization and application of the prefabricated polyurethane track bed block are facilitated.

Drawings

The accompanying drawings, which are included to provide a further understanding of the embodiments of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principles of the invention. In the drawings:

FIG. 1 is a schematic structural diagram of an embodiment of the present invention;

FIG. 2 is a schematic structural diagram of a product obtained by an embodiment of the present invention;

FIG. 3 is a schematic structural diagram of a mold before casting in an embodiment of the present invention;

FIG. 4 is a schematic structural view of the mold with the locking cover assembled thereon according to an embodiment of the present invention;

FIG. 5 is a schematic view of a locking cover according to an embodiment of the present invention;

FIG. 6 is a schematic diagram of the vibration of the tap assembly on the zaar stone in an embodiment of the present invention;

FIG. 7 is a schematic diagram of a product inspection mechanism according to an embodiment of the present invention;

FIG. 8 is a schematic view of a polyurethane track bed block product during testing in accordance with an embodiment of the present invention;

FIG. 9 is a side view of a mold release according to an embodiment of the present invention;

FIG. 10 is a schematic structural view showing the detection of the density of rare earths according to an embodiment of the present invention;

fig. 11 is a schematic structural diagram of a mold for detecting the density of the gravel according to the embodiment of the invention.

Reference numbers and corresponding part names in the drawings:

1-mould, 2-locking cover, 3-vibration assembly, 4-polyurethane track bed block, 5-rail, 6-injection manipulator, 7-foaming machine, 8-hydraulic system, 9-control box, 10-product detection mechanism, 11-sleeper, 12-second bearing body, 13-mechanical arm, 14-first bearing body, 15-mould box, 16-baffle, 17-jacking mechanism, 18-fixing plate, 19-floating pressing plate, 20-guide column, 21-pressing air bag, 22-support, 23-locking hook, 24-mounting frame, 25-vibration table, 26-lifting oil cylinder, 27-vibration motor, 28-guide assembly, 29-holding device and 30-positioning piece, 31-mounting plate, 32-connecting rod, 33-displacement detection device, 34-pressure transmission piece and 35-jacking middle column.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is further described in detail below with reference to examples and accompanying drawings, and the exemplary embodiments and descriptions thereof are only used for explaining the present invention and are not meant to limit the present invention. In the description of the present application, it is to be understood that the terms "front", "back", "left", "right", "upper", "lower", "vertical", "horizontal", "high", "low", "inner", "outer", etc. indicate orientations or positional relationships based on those shown in the drawings, and are only for convenience in describing the present invention and simplifying the description, but do not indicate or imply that the device or element being referred to must have a particular orientation, be constructed in a particular orientation, and be operated, and thus should not be construed as limiting the scope of the present application.

Example 1:

the complete equipment for producing and detecting the polyurethane track bed block as shown in fig. 1 comprises a mould 1 matched with a sleeper 11, a locking cover 2 for sealing the mould 1 and a foaming machine 7 for foaming polyurethane; and the vibration compaction component 3 is further included, and the vibration compaction component 3 is used for pressurizing the inside of the mould 1 and providing vibration. The embodiment comprises a rail 5, wherein the mould 1 is detachably connected to the rail 5, and the mould 1 can move along the rail 5; the tap assembly 3 is fixedly connected to the track 5.

The production line as shown in figure 1 is formed through the track in the embodiment, the length (namely the total length of the equipment) of the whole line is less than 17m, the transportation capacity of a large truck is met, the mould, the foaming machine and the track with the jolt ramming component can be conveniently moved to a workshop near a corresponding operation site for temporary installation, the equipment can be flexibly moved along with the change of construction projects or operation sites, the requirement of nearby production can be met, the transportation cost of prefabricated products is remarkably reduced, and the popularization and application of the prefabricated polyurethane track bed block are facilitated.

The using process of the embodiment comprises the following steps: firstly, a sleeper and stones are filled in a mould, then the mould is integrally moved to the position of a vibration assembly, the vibration assembly vibrates and compacts the interior of the mould downwards until the density of the stones in the mould meets the requirement, then polyurethane raw materials are poured into the mould through a foaming machine, the polyurethane raw materials after high-pressure mixing are injected into the mould and enter gaps between the stones and the sleeper and are fully filled, the mould is sealed through a locking cover immediately after the raw materials are injected, the polyurethane raw materials are waited to be fully foamed until the polyurethane raw materials are cured, then the locking cover is opened, demoulding and taking out are carried out, a polyurethane ballast block product shown in figure 2 is obtained, the vibration assembly presses the product again, and the deformation under the specified pressure is detected, so that whether the product meets the requirement is judged.

The applicant verifies that the compacting effect of the zaki is remarkably improved by compacting the vibration of the compacting component simultaneously, compared with a mode of compacting alone or vibrating alone or compacting and vibrating separately.

Example 2:

on the basis of embodiment 1, as shown in fig. 1 to 11, the complete equipment for producing and detecting the polyurethane track bed blocks further comprises a mechanical arm 13 matched with the locking cover 2, wherein the mechanical arm 13 is used for taking and placing the locking cover 2.

As shown in fig. 5, the locking cover 2 includes a fixing plate 18, a floating pressing plate 19, and a bracket 22; the floating compression plate 19 is movably matched below the fixed plate 18 through a guide post 20, and a compression air bag 21 is arranged between the fixed plate 18 and the floating compression plate 19; the support 22 is connected above the fixing plate 18, a locking hook 23 used for hooking the mould 1 is arranged on the support 22, and the mechanical arm 13 is matched with the support 22.

As shown in fig. 3 and 4, the mold 1 includes a first supporting body 14 and two mold boxes 15 located on the first supporting body 14, wherein a first gap for exposing the sleeper 11 is formed at the bottom of each mold box 15, a second gap is formed at each of opposite sides of the two mold boxes 15, and the bottom shape of the second gap is matched with the inverted sleeper 11; the sleeper mould also comprises a baffle plate 16 which is detachably connected with the mould boxes 15, when the sleeper 11 is placed in the two mould boxes 15, the sleeper 11 is filled in the first gap, and the baffle plate 16 is used for blocking the second gap.

The cross section of the bottom of the mold box 15 is in the shape of an inverted trapezoid in the embodiment, and the sleeper is placed in an inverted mode, so that when a product is placed in the molding forward direction, polyurethane blocks which are in the shape of a trapezoid at the bottom and are tightly combined with the sleeper can be obtained.

In this embodiment, the overall longitudinal section of the mold box 15 is also in the shape of an inverted trapezoid, and the width of the mold box 15 is gradually reduced from top to bottom; the longitudinal section is a longitudinal section in a direction perpendicular to a line connecting the two mold boxes 15.

As shown in fig. 1 and 9, the device further comprises a jacking mechanism 17 matched with the first notches at the bottoms of the two mold boxes 15, and a limiting mechanism matched with the jacking mechanism 17, wherein the jacking mechanism 17 is used for jacking the sleeper 11, and the limiting mechanism is used for limiting the mold boxes 15 to move upwards when the sleeper 11 is jacked.

The tapping assembly 3, as shown in fig. 6, includes a mounting frame 24 capable of accommodating the die 1, a vibration table 25 located in the mounting frame 24, a lift cylinder 26 for pressing the vibration table 25 downward, a vibration motor 27 for driving the vibration table 25 to vibrate, and a guide assembly 28 for guiding the lifting of the vibration table 25.

The product detection mechanism 10 can move on the track 5, and as shown in fig. 7, the product detection mechanism 10 comprises a second carrier 12, and a containing device 29 positioned on the second carrier 12, wherein the containing device 29 is used for containing the polyurethane track bed block which is placed in the forward direction; the detection device also comprises a detection assembly detachably connected with the product detection mechanism 10 and the die 1, wherein the detection assembly comprises a positioning piece 30 and a mounting plate 31 which are distributed up and down, the positioning piece 30 is connected with the mounting plate 31 through a connecting rod 32, and a plurality of displacement detection devices 33 are arranged on the positioning piece 30; the pressure transmitter 34 is further included, and the displacement detecting device 33 is used for detecting the downward displacement of the pressure transmitter 34. The displacement detecting means 33 uses a dial indicator in this embodiment.

In one or more embodiments, climbing mechanism 17 includes two hydro-cylinders, is located two jacking intermediate pillars 35 of mould bottom, stop gear is including being located the connecting plate on the mould and being located the spacing card on the track, when needs drawing of patterns, moves the mould to climbing mechanism top, makes two jacking intermediate pillars 35 just to two hydro-cylinders, and the connecting plate on the mould just in time moves the below of spacing card simultaneously, starts two hydro-cylinders and upwards jacks this moment, can accomplish the drawing of patterns operation promptly, and has realized the spacing to the mould simultaneously.

In one or more embodiments, the first carrier 14 and the second carrier 12 are each a cart that is in rolling engagement with the track 5.

In one or more embodiments, the track is formed by splicing a plurality of sections, each 3m in length according to the production capacity.

In one or more embodiments, the foaming machine is a high-pressure foaming machine, the output end of the high-pressure foaming machine is connected with the material injection mechanical arm, and the material injection mechanical arm is used for performing accurate material injection, so that the control on the total material injection amount, the material injection path, the material injection uniformity and the like can be well realized.

In one or more embodiments, the product detection mechanism 10 and the mold 1 are respectively located on two sides of the jolt ramming assembly 3 on the track, so that mutual interference is avoided, cross operation is facilitated, and prefabrication efficiency of the polyurethane track bed block is improved.

Example 3:

the complete production and detection system for the polyurethane track bed blocks as shown in fig. 1 to 9 comprises a pretreatment station, a compaction station and an injection station; the device also comprises a mould 1 capable of moving among a pretreatment station, a compaction station and an injection station, a product detection mechanism 10 and a locking cover 2 for sealing the mould 1;

the compaction station is provided with a compaction component 3 for applying pressure to the interior of the die 1 and providing vibration;

and the material injection station is provided with a foaming machine 7 for foaming polyurethane.

The system comprises the following production detection methods:

s1, placing the mold 1 at a pretreatment station, spraying a release agent on the inner wall of the mold, inversely placing the sleeper 11 into the mold 1, and sealing the contact part of the mold 1 and the sleeper 11 through a sealing device;

s2, as shown in fig. 3, filling the hybrid stones into the mold 1 to a set height, so that the hybrid stones reach the set height;

s3, as shown in fig. 6, moving the mold 1 to a tap station, and pressing the stones and sleepers 11 in the mold 1 downwards through the tap assembly 3 with vibration;

s4, moving the die 1 to a material injection station, and injecting a polyurethane foaming raw material into the die 1 through a foaming machine 7; after the injection is finished, the locking cover 2 is covered for locking, the pressing air bag 21 in the locking cover 2 is inflated, and the pressing air bag 21 continuously maintains pressure and applies pressure to the stones in the mold 1 through the floating pressing plate 19, and the state is shown in fig. 4;

s5, moving the mold 1 back to a pretreatment station, and waiting for curing at the pretreatment station, or moving the mold 1 integrally away for curing;

s6, after curing, taking down the locking cover 2, pressing the molded polyurethane track bed block upwards to eject out, and completing demolding, wherein the demolding is shown in figure 9; then taking out the demoulded polyurethane roadbed block to obtain a product shown in figure 2, and placing the product on the product detection mechanism 10 in the forward direction;

s7, mounting a detecting component on the product detecting mechanism 10, as shown in fig. 7 and 8, moving the product detecting mechanism 10 to a tapping position, applying a set pressure downward to the sleeper 11 by the tapping component 3, and detecting the deformation amount of the sleeper 11 under the rated pressure by the detecting component: if the deformation amount of the sleeper 11 is smaller than the standard threshold value, the product is qualified; otherwise, the product is unqualified.

The detection basis of the embodiment is TJ/GW164-2020 temporary technical condition of the fabricated polyurethane elastic track bed block, which is made by the national railway group Co., Ltd. of China, and the detection standard is that the deformation amount is required to be less than 0.6mm under the pressure of 40 KN.

Through the field experiments of the applicant, the deformation amount of the polyurethane ballast bed block product produced by the embodiment is only 0.3mm and can completely meet the standard requirements by detecting in the step S7.

In a more preferred embodiment, the detection of the density of the zeza is further performed between steps S3 and S4, and the method comprises the following specific steps: firstly, as shown in fig. 11, a detection assembly is installed on a mold, then the mold is integrally moved to a position below a tap assembly, as shown in fig. 10, a set pressure is applied to the ballast blocks after the interior of the mold is tapped through the tap assembly, the detection assembly detects downward deformation of the ballast blocks, the deformation is compared with a preset value, if the deformation is smaller than the preset value, sufficient tap is indicated, if the deformation is larger than the preset value, insufficient tap is indicated, and the tap assembly is required to be continuously used for vibrating and compacting the loaded ballast blocks.

The above-mentioned embodiments are intended to illustrate the objects, technical solutions and advantages of the present invention in further detail, and it should be understood that the above-mentioned embodiments are merely exemplary embodiments of the present invention, and are not intended to limit the scope of the present invention, and any modifications, equivalent substitutions, improvements and the like made within the spirit and principle of the present invention should be included in the scope of the present invention.

It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, the term "connected" used herein may be directly connected or indirectly connected via other components without being particularly described.

Claims (5)

1. A complete set of equipment for producing and detecting a polyurethane track bed block is characterized by comprising a mould (1) matched with a sleeper (11), a locking cover (2) used for sealing the mould (1), and a foaming machine (7) used for foaming polyurethane; the mould further comprises a tap assembly (3), wherein the tap assembly (3) is used for pressing the interior of the mould (1) and providing vibration;

the mould is characterized by further comprising a rail (5), wherein the mould (1) is detachably connected to the rail (5), and the mould (1) can move along the rail (5); the compaction component (3) is fixedly connected to the track (5);

the product detection mechanism (10) can move on the track (5), the product detection mechanism (10) comprises a second bearing body (12) and a containing device (29) positioned on the second bearing body (12), and the containing device (29) is used for containing the polyurethane track bed block which is placed in the forward direction;

the die (1) comprises a first bearing body (14) and two die boxes (15) positioned on the first bearing body (14), wherein a first notch used for exposing the sleeper (11) is formed in the bottom of each die box (15), second notches are formed in the sides, opposite to each other, of the two die boxes (15), and the bottom of each second notch is matched with the inverted sleeper (11) in shape; the sleeper (11) is filled in the first gap when the sleepers (11) are placed in the two mould boxes (15), and the baffle plate (16) is used for plugging the second gap; the width of the mould box (15) is gradually reduced from top to bottom;

the mould box lifting mechanism is characterized by further comprising a lifting mechanism (17) matched with first gaps at the bottoms of the two mould boxes (15) and a limiting mechanism matched with the lifting mechanism (17), wherein the lifting mechanism (17) is used for lifting the sleeper (11), and the limiting mechanism is used for limiting the mould boxes (15) to move upwards when the sleeper (11) is lifted;

the compaction assembly (3) comprises a mounting frame (24) capable of accommodating the die (1), a vibration table (25) positioned in the mounting frame (24), a lifting oil cylinder (26) used for pressing the vibration table (25) downwards, a vibration motor (27) used for driving the vibration table (25) to vibrate, and a guide assembly (28) used for guiding the lifting of the vibration table (25);

the detection assembly is detachably connected with the product detection mechanism (10) and the mold (1), the detection assembly comprises a positioning piece (30) and a mounting plate (31) which are vertically distributed, the positioning piece (30) is connected with the mounting plate (31) through a connecting rod (32), and a plurality of displacement detection devices (33) are arranged on the positioning piece (30); the device also comprises a pressure transmitter (34), and the displacement detection device (33) is used for detecting the downward displacement of the pressure transmitter (34).

2. The polyurethane track bed block production and detection complete equipment according to claim 1, characterized by further comprising a mechanical arm (13) matched with the locking cover (2), wherein the mechanical arm (13) is used for picking and placing the locking cover (2).

3. The polyurethane track bed block production and detection plant as claimed in claim 2, wherein the locking cover (2) comprises a fixed plate (18), a floating pressure plate (19), a bracket (22); the floating compression plate (19) is movably matched below the fixed plate (18) through a guide post (20), and a compression air bag (21) is arranged between the fixed plate (18) and the floating compression plate (19); the support (22) is connected above the fixing plate (18), a locking hook (23) used for hooking the mold (1) is arranged on the support (22), and the mechanical arm (13) is matched with the support (22).

4. A polyurethane track bed block production detection complete system based on the complete equipment of any one of claims 1-3 is characterized by comprising a pretreatment station, a compaction station and a material injection station; the device also comprises a mould (1) capable of moving among a pretreatment station, a compaction station and an injection station, a product detection mechanism (10) and a locking cover (2) for sealing the mould (1);

the compaction station is provided with a compaction assembly (3) for applying pressure to the interior of the die (1) and providing vibration;

and the material injection station is provided with a foaming machine (7) for foaming polyurethane.

5. The use method of the complete set of polyurethane track bed block production detection system according to claim 4,

s1, placing the die (1) at a pretreatment station, spraying a release agent on the inner wall of the die (1), inversely placing the sleeper (11) into the die (1), and sealing the contact part of the die (1) and the sleeper (11) through a sealing device;

s2, filling the zechu stones in the mold (1) to a set height, so that the zechu stones reach the set height;

s3, moving the mold (1) to a compaction station, and pressing the stones and the sleepers (11) in the mold (1) downwards through the compaction assembly (3) along with vibration;

s4, moving the die (1) to a material injection station, and injecting a polyurethane foaming raw material into the die (1) through a foaming machine (7); after the injection is finished, the locking cover (2) is covered for locking, the pressing air bag (21) in the locking cover (2) is inflated, and the pressing air bag (21) continuously maintains pressure and applies pressure to the stones in the die (1) through the floating pressing plate (19);

s5, moving the die (1) back to a pretreatment station, and waiting for curing at the pretreatment station, or moving the die (1) integrally for curing;

s6, after curing is completed, the locking cover (2) is taken down, the molded polyurethane track bed block is pressed upwards to be ejected out, demoulding is completed, the demoulded polyurethane track bed block is taken out, and the polyurethane track bed block is placed on the product detection mechanism (10) in the forward direction;

s7, mounting a detection component on the product detection mechanism (10), wherein the detection component is used for detecting the displacement of the sleeper (11) under the rated pressure; move product detection mechanism (10) to the tap station, exert the settlement pressure through tap subassembly (3) to sleeper (11) downwards, detect the deformation volume of sleeper (11): if the deformation amount of the sleeper (11) is smaller than the standard threshold value, the product is qualified; otherwise, the product is unqualified.

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