CN212241537U - Automatic and unmanned production system for double-block type sleeper - Google Patents

Abstract

The utility model discloses a two block type sleeper automation, unmanned production system, including mould detection device, spout release agent device, sleeve pipe spiral muscle installation and reinspection device, truss stirrup installation and reinspection device, mix earth and pour the device, steam curing means, sleeper detection device, sleeper buffer memory curing means, truss stirrup assembly quality, blow notes spiral muscle device and control center, still including the mould cleaning device who has dual screening function and the sleeper shedder who has multidirectional transport function, control center is connected with the executive component electricity of above-mentioned each device, annular automatic cycle's semi-manufactured goods production line and a finished sleeper production line are constituteed to above-mentioned device. All devices in the system can realize automatic operation without manually operating each device, so that the labor cost can be saved, and the sleeper production efficiency is improved.

Description

Automatic and unmanned production system for double-block type sleeper

Technical Field

The utility model relates to a sleeper production facility field, in particular to automatic, the unmanned production system of double block formula sleeper.

Background

Along with the rapid development of high-speed railways, the demand for sleepers is more and more large, and in order to meet the requirements, the requirements of factories on the intelligent production of sleeper prefabrication are higher and higher, and the traditional production mode can not meet the requirements of development. Firstly, the most advanced sleeper production line in the industry at present has low full automation degree, for example, part of operations are completely completed manually in the production process, and other parts of operations are completed only by manual assistance, so that the sleeper production efficiency is low, and meanwhile, the problems of construction quality key links, lack of quality control means and the like are solved; secondly, the layout of the traditional production plant of the sleeper plant has problems, and the full automation of all production procedures can not be met, so that the aim of seamless connection among all production procedures can not be achieved.

SUMMERY OF THE UTILITY MODEL

The utility model aims to overcome the not enough of prior art, provide two formula sleeper automation, unmanned production system.

The purpose of the utility model is realized through the following technical scheme:

the automatic and unmanned production system for the double-block type sleeper comprises a mould detection device, a mold release agent spraying device, a sleeve spiral rib installation and rechecking device, a truss stirrup assembling device, a concrete pouring device with an accurate material distribution component, a steam curing device, a sleeper detection device, a blowing, injecting and buckling device, a control center and a sleeper caching and curing device, and further comprises a mould cleaning device with a double screening function and a sleeper demolding device with a multidirectional conveying function;

the control center is electrically connected with the execution components of the devices;

the sleeper demoulding device is provided with a semi-finished product input end for conveying a semi-finished product into the sleeper demoulding device, a finished product output end for conveying a sleeper into the sleeper detection device and a mould output end for conveying a mould into the mould cleaning device;

the mould cleaning device, the mould detection device, the mould release agent spraying device, the sleeve spiral rib mounting and rechecking device, the truss stirrup mounting and rechecking device, the concrete pouring device, the steam curing device and the sleeper demoulding device are sequentially connected to form an automatic circulating semi-finished product production line;

the mould cleaning device, the mould detection device, the release agent spraying device, the sleeve spiral rib mounting and rechecking device, the truss stirrup mounting and rechecking device, the concrete pouring device, the steam curing device, the pillow demoulding device, the pillow detection device, the blowing injection buckling device and the sleeper caching and curing device are sequentially connected to form a finished product production line for producing the sleeper;

the truss stirrup installing and rechecking device is connected with the output end of the truss stirrup assembling device.

Furthermore, the mould cleaning device comprises a carborundum spray head for cleaning a mould, the carborundum spray head is arranged on the upper side of the interior of the sand return funnel, a roller way for conveying the mould is arranged on the upper side of the sand return funnel, a sand blasting shell connected with the sand return funnel is arranged on the upper side of the roller way, a vibrating screen assembly and two sand boxes are arranged on the upper plane of the sand blasting shell, the two sand boxes are respectively positioned on two sides of the vibrating screen assembly, the sand boxes are connected with the vibrating screen assembly through a sand feeding auger, the input end of the vibrating screen assembly is connected with a first sand return auger, a discharge pipe for removing mixed soil residues is further arranged on the vibrating screen assembly, a second sand return auger is arranged on the sand return funnel, and the first sand return auger is connected with the second sand return auger through a carborundum conveyer belt;

the emery return hopper is also internally provided with an emery screen for screening emery, a fixing rod is arranged on the upper side of the emery screen, a plurality of emery spray heads are arranged on the fixing rod, the emery spray heads are also provided with a sand inlet, an air inlet and a spray opening, the sand inlet is connected with the sand box, and the air inlet is connected with an air compressor on the outer side;

the upper plane of the sand blasting shell is also provided with a dust removal pipeline, the input end of the dust removal pipeline is connected to the inside of the sand blasting shell, the output end of the dust removal pipeline is provided with a dust removal box, and the dust removal box is provided with a filter screen rotating motor for extracting dust in the sand blasting shell;

and the first sand-returning packing auger, the second sand-returning packing auger and the sand-returning hopper are all provided with packing auger rotating motors for providing power for conveying carborundum.

Further, the sleeve spiral rib mounting and rechecking device comprises a coil spring component for processing the spiral rib, a sleeve storage component for storing the sleeve, a sleeve spiral rib fastening component for screwing the spiral rib and the sleeve into the sleeve assembly, the sleeve helical rib fastening member is disposed between the coil spring member and the sleeve storage member, a sleeve spiral rib conveying belt is arranged on the lower side of the sleeve spiral rib fastening part, a sleeve sorting part for moving the sleeve from the sleeve storing part to the upper side of the sleeve spiral rib conveying belt is arranged between the sleeve spiral rib fastening part and the sleeve storing part, a spiral rib mounting component which moves the spiral rib from the coil spring component to the upper side of the sleeve spiral rib conveying belt is arranged between the sleeve spiral rib fastening component and the coil spring component;

the sleeve spiral rib mounting and rechecking device further comprises a sleeve assembly mounting frame, the sleeve assembly mounting frame is provided with a component for rechecking the sleeve assembly, the sleeve spiral rib mounting component is used for detecting the sleeve assembly, the lower side of the sleeve spiral rib mounting component is provided with a mold conveying roller way for conveying the mold, the sleeve spiral rib mounting frame is arranged between the sleeve spiral rib fastening components, and the sleeve spiral rib fastening components are provided with a sleeve assembly manipulator which is used for moving the sleeve spiral rib fastening components to the sleeve spiral rib placing platform.

Furthermore, the truss stirrup assembling device comprises a truss stirrup assembling component, a truss feeding component and a stirrup feeding component, wherein the truss feeding component and the stirrup feeding component are arranged on two sides of the truss stirrup assembling component;

the stirrup feeding part comprises a stirrup conveying roller way for conveying stirrups and a stirrup conveying assembly for transferring the stirrups from the reinforcement hopper assembly to the stirrup conveying roller way, and the output end of the stirrup conveying roller way is connected with the truss stirrup assembling part;

the truss feeding component comprises a truss feeding outer frame component, first truss clamping claw pieces used for clamping, overturning and moving the steel bar truss are symmetrically arranged on the truss feeding outer frame component, a truss receiving table used for supporting the steel bar truss is arranged on the lower side of each first truss clamping claw piece, a truss conveying table used for conveying the truss receiving table is arranged on the lower side of the truss receiving table, a movable truss storage table is arranged on the input side of the truss conveying table, and an inverted triangle used for preventing the steel bar truss from deflecting and matched with truss stirrups is arranged at the upper end of the truss receiving table;

the truss stirrup assembling part comprises a stirrup conveying belt which is connected to the output end of the stirrup conveying roller way and is used for conveying the steel stirrups, the output end of the stirrup conveying belt is provided with a truss stirrup assembling outer frame, a second truss clamping claw piece used for clamping the steel bar truss is arranged on the truss stirrup assembling outer frame, the truss stirrup assembling outer frame is connected with the output end of the truss conveying belt, the truss conveying belt and the stirrup conveying belt are oppositely arranged, one side of the input end of the truss conveying belt is in contact with the output end of the truss conveying table, and the upper side of the truss conveying belt is provided with a third truss clamping claw piece used for conveying the steel bar truss from the truss bearing table to the truss conveying belt;

the truss stirrup assembling part also comprises a hook clamping piece for clamping a hook and a hook conveying belt for conveying the hook clamping piece, the output end of the hook conveying belt is positioned at the lower side of the second truss clamping piece, and the input end of the hook conveying belt is provided with a hook storage component for storing the hook;

the truss stirrup assembling component further comprises a truss stirrup mounting component for mounting the hook on the steel bar truss, the truss stirrup mounting component further mounts the steel stirrup on the hook, and the hook and the steel stirrup are mounted on the steel bar truss to form a truss stirrup;

the output end of the truss stirrup assembling device is the second truss clamping piece, the second truss clamping piece clamps the truss stirrups to move on the truss stirrup assembling outer frame, and the truss stirrups are placed into the truss stirrup installing and rechecking device.

Furthermore, the sleeper demoulding device comprises a truss outer frame component, the truss outer frame component comprises a truss beam component, a storage component used for temporarily storing the semi-finished product is arranged on the lower side of the truss beam component, a demoulding component used for separating the mould and the sleeper is further arranged on the lower side of the truss beam component, a mould clamping component used for conveying and overturning the semi-finished product is connected to the truss beam component, and the mould clamping component is located on the upper side of the storage component and can convey the semi-finished product to the demoulding component;

further, the concrete pouring device comprises a feeding part which conveys concrete from the stirring part to the precise distributing part, the accurate material distributing part comprises a material distributing machine hopper with a quantitative material loading function, a plurality of weighing container assemblies are arranged on the lower side of the material distributing machine hopper, a plurality of closable first feed openings are arranged at the bottom of the hopper of the distributing machine, each first feed opening is correspondingly arranged right above the weighing container assembly, a closable second feed opening is arranged at the lower side of the weighing container component, a feed opening driving component for opening/closing the second feed opening is arranged on the second feed opening, outlets of the second feed openings are all arranged on the upper side of the inner cavity of the mold, the accurate material distribution part is provided with a stirring assembly for preventing concrete from being condensed, and the accurate material distribution part and the feeding part are both arranged on a support with a guide rail;

two groups of heavy container assemblies are arranged on the lower side of the hopper of the distributing machine, each group is provided with four heavy container assemblies, and the volumes of all the heavy container assemblies are equal;

the concrete pouring device further comprises a vibration component used for tamping concrete.

Further, the demolding assembly comprises symmetrically arranged action parts, each action part comprises a jacking table, a demolding table and a detection table, the detection tables on two sides are arranged between the demolding tables on two sides, and the demolding tables on two sides are arranged between the jacking tables on two sides;

the detection tables on two sides are respectively provided with a plurality of detection pieces for detecting the completion of the separation of the die and the sleeper;

a die pillow conveying track is arranged between the detection tables on the two sides, a sleeper conveying assembly and a die conveying assembly are arranged on the die pillow conveying track, and third jacking pieces are arranged on the sleeper conveying assembly and the die conveying assembly;

the end, where the storage assembly is located, of the sleeper demolding device is a semi-finished product input end and is connected with the steam curing device, the end, where the sleeper transportation assembly is located, of the sleeper demolding device is a finished product output end and is connected with the sleeper detection device, and the end, where the mold transportation assembly is located, of the sleeper demolding device is a mold output end and is connected with the mold cleaning device;

the first jacking piece, the second jacking piece and the third jacking piece are all jacking cylinders.

Furthermore, the blowing injection buckling device comprises a sleeper transmission rail for conveying the double-block sleepers, manipulator components with motion functions are arranged on two sides of the sleeper transmission rail, and an integrated and rotatable base is arranged at the end part of the upper side of each manipulator component;

the base is provided with a 3D camera which has monitoring and can be positioned, an air blowing port connected with the air supply assembly, an oil filling port connected with the oil supply assembly and a cover buckling assembly for buckling and covering the sleeve hole cover;

the upper surface of the base is connected with the manipulator component, the buckle cover component is arranged on the lower surface of the base, and the 3D camera, the air blowing port and the oil filling port are all arranged on the side surface of the base;

the buckle cover assembly comprises a picking piece matched with an inner hole at the end part of the buckle cover, a through hole is formed in the picking piece, and a pressing piece which can move along the through hole and is used for pressing the buckle cover into a sleeve hole on a sleeper is arranged in the through hole;

the input end of the pressing piece is connected with a piston on a cylinder, and a cylinder body of the cylinder is arranged inside the base.

Further, the control center comprises a start button for starting the production system and a stop button for closing the production line;

the die is provided with a sleeve assembly mounting position, a truss stirrup mounting position and a die number;

the die detection device comprises a first laser image detection component with an image detection function, a die identification component for identifying a die number and a die selection component for selecting a damaged die;

the demolding agent spraying device comprises a demolding agent spraying part filled with a demolding agent and a turning part used for turning the mold to an inner cavity of the mold upwards;

the truss stirrup installation and rechecking device comprises a second rechecking component for detecting the truss stirrups and the installation positions of the truss stirrups;

the sleeper detection apparatus includes a second laser image detection unit having an image detection function, a sleeper recognition unit for detecting the sleeper, and a code printing unit for printing a code.

The utility model has the advantages that:

1) all devices in the system can realize automatic operation without manually operating each device, so that the labor cost can be saved, and the efficiency of producing the sleeper is improved because the automation degree of the production line is improved.

2) The system enters a mold cleaning station after the mold is demolded, and forms an annular mold self-circulation use line, so that the mold can be fully utilized, seamless connection of the production line is realized, and the automation degree of the production line is higher.

3) The automatic mould cleaning is improved from manual mould cleaning in the mould cleaning device, the carborundum used for mould cleaning is recycled, the cost can be effectively saved, a filter screen rotating motor is arranged in a dust removing box, and dust generated in the mould cleaning process can be effectively absorbed, so that the production line cannot be polluted by the dust generated in the mould cleaning process.

4) In the concrete pouring device, the process that the muddy earth in the pay-off part adds the cloth machine hopper can carry out the accuse material for the first time, the muddy earth in the cloth machine hopper gets into the container subassembly of weighing and carries out the accurate accuse material for the second time, because the volume of the container subassembly of weighing is the same, the volume that every required muddy earth of inner chamber is the same in every container subassembly of weighing and the mould simultaneously, once only all muddy earth of weighing in the container subassembly of will every is put into and just can satisfy the needs of production, reach the purpose of the accurate accuse material completely.

5) The blowing injection buckling device can blow air to the sleeve hole of the sleeper, impurities in the sleeve hole can be removed through blowing air, oil is injected into the sleeve hole after the impurities are removed, and a buckling cover is covered on the outer side of the sleeve hole after the oil is injected. The three devices are needed in the traditional production process to complete the work task, the automatic production line can complete the operation in one device, the length of the production line can be reduced, the space is saved, the sleepers do not need to be moved in the three processes, the time cost can be saved, and the energy consumption is reduced.

Drawings

FIG. 1 is a schematic top view of a sleeper;

FIG. 2 is a schematic top view of the mold;

FIG. 3 is a schematic view of a connection configuration of the production line;

FIG. 4 is a schematic structural view of a mold cleaning apparatus;

FIG. 5 is a schematic view of a partial structure of the interior of the mold cleaning apparatus;

FIG. 6 is a schematic structural view of a corundum spray head;

FIG. 7 is a schematic view of a connection structure of the casing spiral rib installation and review device;

FIG. 8 is a schematic view of a connection structure of the stirrup feeding part;

FIG. 9 is a schematic view of a connection structure of the truss loading part;

FIG. 10 is a schematic view of the connection structure of the truss stirrup assembly;

FIG. 11 is an enlarged view of FIG. 10 at A;

FIG. 12 is a schematic view of the connection structure of the concrete placement device;

FIG. 13 is a schematic front view of a precision distributing unit;

FIG. 14 is a schematic top view of the precision cloth component;

FIG. 15 is a schematic view showing a connecting structure of the ejector;

FIG. 16 is a schematic view of the connection structure of the blow-molding button attaching apparatus;

FIG. 17 is a schematic view of the connection structure of the end portions of the robot parts;

FIG. 18 is a front view of a robot end connection;

in the figure, 1-a mould cleaning device, 2-a mould detection device, 3-a release agent spraying device, 4-a sleeve spiral rib installation and rechecking device, 5-a precise material distribution component, 6-a truss stirrup installation and rechecking device, 7-a truss stirrup assembly device, 8-a concrete pouring device, 9-a steam curing device, 10-a sleeper demoulding device, 11-a sleeper detection device, 12-a sleeper, 13-a blowing injection buckling device, 14-a mould, 15-a control center, 16-a sleeper caching and curing device, 17-a discharge pipe, 18-a carborundum spray head, 19-a sand return funnel, 20-a roller way, 21-a sand blasting shell, 22-a vibrating screen assembly, 23-a sand box, 24-a sand feeding auger and 25-a first sand return auger, 26-a second sand-returning auger, 27-a carborundum conveyer belt, 28-a carborundum screen, 29-a fixed rod, 30-a sand inlet, 31-a dedusting pipeline, 32-a dedusting box, 33-a filter screen rotating motor, 34-an auger rotating motor, 35-a sleeper transmission rail, 36-a manipulator component, 37-a base, 38-a 3D camera, 39-an air blowing port, 40-an oil filling port, 41-a cover buckling component, 42-an air inlet, 43-an injection port, 44-a truss beam component, 45-a storage component, 46-a demoulding component, 47-a mould clamping component, 48-a jacking platform, 49-a demoulding platform, 50-a detection platform, 51-a first jacking component, 52-a second jacking component and 53-a detection component, 54-a mould sleeper conveying track, 55-a sleeper conveying component, 56-a mould conveying component, 57-a third jacking component, 58-a stirrup conveying roller way, 59-a stirrup conveying component, 60-a steel bar funnel component, 61-a truss loading outer framework component, 62-a first truss jaw component, 63-a truss receiving platform, 64-a truss conveying platform, 65-a truss storage platform, 66-a stirrup conveying belt, 67-a truss stirrup assembly outer framework, 68-a second truss jaw component, 69-a truss conveying belt, 70-a third truss jaw component, 71-a hook clamping component, 72-a hook conveying belt, 73-a truss stirrup mounting component, 74-a truss stirrup, 75-a sleeve hole, 76-a label, 77-a sleeve component mounting position, 78-truss stirrup mounting position, 79-coil spring component, 80-sleeve storage component, 81-sleeve spiral rib fastening component, 82-sleeve spiral rib conveying belt, 83-sleeve sorting component, 84-spiral rib mounting component, 85-sleeve assembly mounting rack, 86-sleeve spiral rib placing table, 87-sleeve spiral rib mounting component, 88-first rechecking component, 89-mold conveying roller way, 90-sleeve assembly manipulator, 91-feeding component, 92-distributing machine hopper, 93-weighing container component, 94-first discharging port, 95-second discharging port, 96-discharging port driving component and 97-stirring component.

Detailed Description

The technical solution of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by those skilled in the art without creative efforts belong to the protection scope of the present invention.

Referring to fig. 3-17, the present invention provides a technical solution:

the sleeper 12 shown in fig. 1 has a structure in which two truss stirrups are arranged in parallel, concrete casting is cast on each truss stirrup, two sleeve holes 75 and two signs 76 are provided on each concrete casting, the sleeve holes 75 are used for installing a fixing member for fixing a steel rail, and the signs 76 are used for engraving other information such as production time, address, and the like.

Referring to the mold 14 shown in fig. 2, the mold 14 can simultaneously produce 4 sleepers 12, and the mold 14 is provided with a sleeve assembly mounting location 77, a truss stirrup mounting location 78 and a mold number.

The automatic and unmanned production system for the double-block type sleeper comprises a mold detection device 2, a release agent spraying device 3, a sleeve spiral rib installation and rechecking device 4, a truss stirrup installation and rechecking device 6, a truss stirrup assembling device 7, a concrete pouring device 8 with an accurate material distribution component 5, a steam curing device 9, a sleeper detection device 11, a blowing injection buckling device 13, a control center 15 and a sleeper caching and curing device 16, and further comprises a mold cleaning device 1 with a double screening function and a sleeper demoulding device 10 with a multidirectional conveying function; the control center 15 is electrically connected with the execution components of the devices; the sleeper stripping device 10 is provided with a semifinished product input for feeding semifinished products into the sleeper stripping device 10, a finished product output for feeding sleepers 12 into the sleeper detection device 11, and a mold output for feeding molds 14 into the mold cleaning device 1.

The device comprises a mould cleaning device 1, a mould detection device 2, a mould release agent spraying device 3, a sleeve spiral rib mounting and rechecking device 4, a truss stirrup mounting and rechecking device 6, a concrete pouring device 8, a steam curing device 9 and a sleeper demoulding device 10 which are sequentially connected and form an automatic circulating semi-finished product production line.

The mould cleaning device 1, the mould detection device 2, the release agent spraying device 3, the sleeve spiral rib mounting and rechecking device 4, the truss stirrup mounting and rechecking device 6, the concrete pouring device 8, the steam curing device 9, the pillow demoulding device 10, the pillow detection device 11, the blowing injection buckling device 13 and the sleeper cache curing device 16 are sequentially connected to form a finished product production line for producing the sleeper 12; the truss stirrup mounting and rechecking device 6 is connected with the output end of the truss stirrup assembling device 7.

The mould cleaning device 1 comprises a carborundum spray head 18 for cleaning a mould, the carborundum spray head 18 is arranged on the upper side of the interior of a sand return funnel 19, the upper side of the sand return funnel 19 is provided with a roller way 20 for conveying the mould, the upper side of the roller way 20 is provided with a sand blasting shell 21 connected with the sand return funnel 19, the upper plane of the sand blasting shell 21 is provided with a vibrating screen assembly 22 and two sand boxes 23, the two sand boxes 23 are respectively positioned on two sides of the vibrating screen assembly 22, the sand boxes 23 are connected with the vibrating screen assembly 22 through a sand feeding auger 24, the input end of the vibrating screen assembly 22 is connected with a first sand return auger 25, the vibrating screen assembly 22 is further provided with a discharge pipe 17 for removing concrete residues, the sand return funnel 19 is provided with a second sand return auger 26, and the first sand return auger 25 is connected with the second sand return auger 26 through a carborundum conveyer.

The return sand hopper 19 is also provided with a carborundum screen 28 for screening carborundum, the upper side of the carborundum screen 28 is provided with a fixing rod 29, a plurality of carborundum spray heads 18 are arranged on the fixing rod 29, the carborundum spray heads 18 are also provided with a sand inlet 30, an air inlet 42 and a spray opening 43, the sand inlet 30 is connected with the sand box 23, and the air inlet 42 is connected with an air compressor on the outer side.

Preferably, a dust removal pipeline 31 is further disposed on the upper plane of the sandblasting housing 21, an input end of the dust removal pipeline 31 is connected inside the sandblasting housing 21, an output end of the dust removal pipeline 31 is provided with a dust removal box 32, and the dust removal box 32 is provided with a filter screen rotating motor 33 for extracting dust inside the sandblasting housing 21. Auger rotating motors 34 for providing power for conveying carborundum are arranged on the first sand-returning auger 25, the second sand-returning auger 26 and the sand-returning hopper 19. Be provided with filter screen rotation motor 33 in dust removal case 32, filter screen rotation motor 33 high-speed rotation can effectual absorption die cleaning in-process produced dust for the production line can not be by die cleaning in-process produced dust pollution, guarantees the environmental quality in workshop.

The entrance and exit of the roller way 20 are provided with door curtains for preventing dust from leaking, and the door curtains, the sand blasting shell 21 and the sand return hopper 19 form a closed mold cleaning space together. The ejection port 43 is provided on the upper end face of the corundum spray head 18 and is disposed vertically upward. The air inlet 42 is provided on the lower end face of the corundum spray head 18. The sand inlet 30 is provided on the side of the emery spray head 18 near the spray opening 43. The emery screen 28 is provided with screening holes for filtering emery.

The process of the mold cleaning apparatus 1 is: the carborundum entering from the carborundum inlet 30 and the high-speed airflow entering from the air inlet 42 are mixed in the carborundum spray head 18, and are sprayed out from the spray opening 43 on the carborundum spray head 18 after being mixed, the high-speed carborundum impacts in the mould, so that the residual muddy soil slag in the mould is impacted by the carborundum and then falls off, and the purpose of mould cleaning is achieved, and the carborundum in the mould cleaning device 1 is firstly screened by the carborundum screen 28. After the first screening, the large-particle soil-mixed slag is left on the carborundum screen 28, the small-particle soil-mixed slag and the carborundum enter the vibrating screen component 22 through the second sand-returning packing auger 26, the carborundum conveying belt 27 and the first sand-returning packing auger 25, and the second screening is carried out on the vibrating screen component 22. After the second screening, the carborundum is separated from the small-particle concrete slag, wherein the carborundum enters the sand box 23 through the sand feeding auger 24, the small-particle concrete slag is discharged through the discharge pipe 17, and the carborundum in the sand box 23 is directly transmitted to the carborundum inlet 30 on the carborundum spray head 18, so that the cyclic utilization of the carborundum can be realized, and the cost can be effectively saved. Meanwhile, a recovery box is arranged at the output end of the discharge pipe 17, and the small-particle concrete slag is discharged into the recovery box. The large-particle concrete slag on the carborundum screen 28 is manually cleaned and discharged. The mould back-buckling type is transmitted to a mould cleaning station through a track in a full-automatic mode, the mould inner cavity is polished in an all-dimensional mode through a sand blasting process, and after sand blasting is completed, residues on the surface of the mould are thoroughly cleaned through an air knife, so that automatic mould cleaning can be met.

In the die detection device 2, a first laser image detection means having an image detection function, a die identification means for identifying a die number, and a die picking means for picking a damaged die are used. Just so can utilize laser image detection technique, the automatic detecting system of sleeper, automatic identification mould number detects, judges to the limit deviation of this mould, sign damaged condition etc. simultaneously, and the formation detects the report, in time picks out the mould that has a problem and maintains.

The release agent spraying device 3 includes a release agent spraying part containing a release agent and an inverting part for inverting the mold 14 with its inner cavity facing upward. The release agent spraying device 3 is a system, the parts are only partial execution parts in the system, and the system adopts a full-automatic control system to spray, so that the automatic positioning and uniform release agent spraying of the mold are realized. After the sensor senses that the mould reachs the assigned position, the shower nozzle aims at the mould inner chamber, with the even spraying of atomizing release agent to the mould intracavity, fog absorbing device can retrieve the atomizing release agent that wafts simultaneously, avoids causing environmental pollution, and release agent recovery unit wraps up whole mould, guarantees that the release agent does not leak, guarantees the environmental sanitation in the place. The newly-increased self-cleaning shower nozzle system prevents that the shower nozzle from blockking up, retrieves simultaneously according to beat automatic control, and is more energy-conserving, and after the spraying was accomplished, with mould upset 180, make the inner chamber get into next process up.

The casing spiral rib mounting and rechecking device 4 comprises a coil spring part 79 for processing spiral ribs, a casing storage part 80 for storing casings, a casing spiral rib fastening part 81 for screwing the spiral ribs and the casings into casing assemblies, the casing spiral rib fastening part 81 is arranged between the coil spring part 79 and the casing storage part 80, a casing spiral rib conveying belt 82 is arranged on the lower side of the casing spiral rib fastening part 81, a casing sorting part 83 for moving the casings from the casing storage part 80 to the upper side of the casing spiral rib conveying belt 82 is arranged between the casing spiral rib fastening part 81 and the casing storage part 80, and a spiral rib mounting part 84 for moving the spiral ribs from the coil spring part 79 to the upper side of the casing spiral rib conveying belt 82 is arranged between the casing spiral rib fastening part 81 and the coil spring part 79.

Casing spiral muscle installation and reinspection device 4 still includes casing assembly mounting bracket 85, be provided with on casing assembly mounting bracket 85 and be arranged in moving casing spiral muscle installing component 87 to the mould 14 from casing spiral muscle put platform 86 with the casing assembly, be provided with the first reinspection part 88 that is used for detecting the casing assembly on the casing spiral muscle installing component 87, the downside of casing spiral muscle installing component 87 is provided with the mould rollgang 89 that is used for carrying mould 14, casing spiral muscle put platform 86 sets up between casing assembly mounting bracket 85 and casing spiral muscle fastening part 81, be provided with on the casing spiral muscle fastening part 81 and move casing assembly manipulator 90 to casing spiral muscle put platform 86 from casing spiral muscle fastening part 81 with the casing assembly.

The casing spiral rib mounting and rechecking device 4 comprises two systems, the parts are only part of execution parts in the two systems, one is a full-automatic casing, spiral rib assembling and mounting platform equipment system, the system comprises a coil spring mechanism, a spiral rib mounting manipulator, a casing storage device, a casing conveying and sorting system, a casing spiral rib conveying belt system, a casing spiral rib fastening clamping jaw, a casing spiral rib stacking manipulator, a casing spiral rib mounting system, a casing spiral rib placing platform and the like, the casing sorting system automatically sorts out the casings according to the specified direction and position, after the spiral rib is grabbed by the coil spring mechanism of the spiral rib mounting machine, the casings are automatically and rotatably assembled on the casings, the casings with the spiral ribs are conveyed to the casing spiral rib fastening clamping jaw through the casing spiral rib conveying belt system, and the spiral ribs are further installed and quality is rechecked, and the casing spiral rib stacking manipulator stacks the casing spiral rib combined piece on the casing spiral rib placing platform. The sleeve spiral rib mounting system respectively identifies the position of the sleeve assembly and the mounting position in the mold cavity through a vision and intelligent sleeve infrared rechecking system, and the sleeve assembly is accurately mounted in the mold. The other is an intelligent sleeve rechecking device equipment system, wherein a position sensor of the system and a torque sensing system of a servo motor detect whether a sleeve assembly is installed in place, the sleeve assembly is installed in place and enters the next procedure, the sleeve assembly cannot be installed in place and continues to be corrected in the procedure, the sleeve assembly enters the next procedure after the correction is completed, and meanwhile, a straight line walking and visual detection system is newly added to recheck and monitor the installation quality of the sleeve.

The truss stirrup assembling device 7 comprises a truss stirrup assembling component, and further comprises a truss feeding component and stirrup feeding components which are arranged on two sides of the truss stirrup assembling component. The stirrup feeding part comprises a stirrup conveying roller way 58 for conveying the steel stirrups, and also comprises a stirrup conveying assembly 59 for conveying the steel stirrups from the steel reinforcement hopper assembly 60 to the stirrup conveying roller way 58, wherein the output end of the stirrup conveying roller way 58 is connected with the truss stirrup assembling part. The truss feeding component comprises a truss feeding outer frame component 61, first truss clamping claw pieces 62 used for clamping, overturning and moving the steel bar truss are symmetrically arranged on the truss feeding outer frame component 61, a truss receiving platform 63 used for supporting the steel bar truss is arranged on the lower side of the first truss clamping claw pieces 62, a truss conveying platform 64 used for conveying the truss receiving platform 63 is arranged on the lower side of the truss receiving platform 63, and a movable truss storage platform 65 is arranged on the input side of the truss conveying platform 64. The upper end of the truss receiving platform 63 is provided with an inverted triangle truss stirrup assembly part which is used for preventing a steel bar truss from deflecting and is matched with the truss stirrup 74, the inverted triangle truss stirrup assembly part comprises a stirrup conveying belt 66 which is connected to the output end of the stirrup conveying roller way 58 and used for conveying steel stirrups, the output end of the stirrup conveying belt 66 is provided with a truss stirrup assembly outer frame 67, a second truss clamping claw piece 68 used for clamping the steel bar truss is arranged on the truss stirrup assembly outer frame 67, the truss stirrup assembly outer frame 67 is connected with the output end of the truss conveying belt 69, the truss conveying belt 69 is arranged opposite to the stirrup conveying belt 66, one side of the input end of the truss conveying belt 69 is in contact with the output end of the truss conveying platform 64, and the upper side of the truss conveying belt 69 is provided with a third truss clamping claw piece 70 for conveying the steel. During the steel stirrup that the welding was accomplished deposited reinforcing bar funnel subassembly 60 through stirrup conveying assembly 59, the steel stirrup carries out the pay-off through the pay-off motor, and stirrup conveying assembly 59 transports stirrup rollgang 58 with the steel stirrup centre gripping through the electromagnetic adsorption principle, through stirrup rollgang 58, transports in the truss stirrup equipment part. The welded steel bar truss is placed on the truss storage platform 65, clamped, turned and moved through the first truss clamping claw piece 62 of the truss feeding component, conveyed to the truss bearing platform 63, and conveyed to the truss stirrup assembling component through the truss conveying platform 64.

The truss stirrup assembly further comprises a hook clamping member 71 for clamping the hook and a hook conveying belt 72 for transporting the hook clamping member 71, the output end of the hook conveying belt 72 is located on the lower side of the second truss jaw member 68, and the input end of the hook conveying belt 72 is provided with a hook storage assembly for storing the hook. The truss stirrup assembling component further comprises a truss stirrup mounting component 73 for mounting the hook on the steel bar truss, the truss stirrup mounting component 73 further mounts the steel stirrup on the hook, and the truss stirrup 74 is formed after the hook and the steel stirrup are mounted on the steel bar truss.

The output end of the truss stirrup assembling device 7 is provided with a second truss clamping piece 68, the second truss clamping piece 68 clamps the truss stirrup 74 to move on the truss stirrup assembling outer frame 67, and the truss stirrup 74 is placed into the truss stirrup installing and rechecking device 6.

The truss stirrup mounting and rechecking device 6 comprises a second rechecking part for detecting the truss stirrups 74 and the truss stirrup mounting positions.

The truss stirrup installation and rechecking device 6 is a system, the parts are only partial execution parts in the system, and the full name of the system is an intelligent truss reinforcement and stirrup automatic installation and rechecking equipment system. The internal truss grabbing and transferring system, the hook mounting system, the truss clamping system, the stirrup clamping and lifting system, the integral transverse moving system, the conveying roller way and the rechecking system. The truss stirrup assembling device automatically assembles a steel bar truss and a steel stirrup and a hook after welding, transports an assembled truss stirrup assembly to a mold, accurately controls the completion of assembling action, and carries out rechecking on the assembled truss through recognizing an accurate positioning and placing position, a recognition buckling and pressing device and an automatic lifting buckling and pressing plate pressing truss.

The concrete pouring device 8 comprises a feeding part 91 for conveying concrete from a stirring part to the accurate distributing part 5, the accurate distributing part 5 comprises a distributing machine hopper 92 with a quantitative material loading function, a plurality of weighing container assemblies 93 are arranged on the lower side of the distributing machine hopper 92, a plurality of closable first discharge ports 94 are arranged at the bottom of the distributing machine hopper 92, each first discharge port 94 is correspondingly arranged right above the weighing container assembly 93, a closable second discharge port 95 is arranged on the lower side of the weighing container assembly 93, a discharge port driving assembly 96 for opening/closing the second discharge port 95 is arranged on the second discharge port 95, outlets of the second discharge ports 95 are all arranged on the upper side of the inner cavity of the mold, the accurate distributing part 5 is provided with a stirring assembly 97 for preventing concrete from being condensed, and the accurate distributing part 5 and the feeding part 91 are both arranged on a support with a guide rail; two groups of heavy container assemblies 93 are arranged on the lower side of the hopper 92 of the distributing machine, each group is provided with four heavy container assemblies 93, and the volumes of all the heavy container assemblies 93 are equal; the concrete casting device 8 also comprises a vibration member for tamping the concrete.

The concrete pouring device 8 is a system, the parts are only part of execution parts in the system, automatic and accurate material distribution equipment is adopted in the system, the control center 15 controls material receiving and discharging, full-automatic material calling is realized, a manual material calling link is saved, and a material distribution link is optimally assisted. The system consists of four parts, namely a distributing machine, a distributing machine cart bracket and a precise metering system; and (3) distributing the concrete into the sleeper mould through a quantitative hopper with a weighing function. And precisely connecting and distributing the materials through the volume and the weight. The spreading distributor is one of the main production equipment of the production line and is the end equipment for conveying concrete. The purpose is to distribute the concrete delivered from the mixing station to the component moulds to be cast on the production line, so as to obtain the concrete prefabricated member required by the design. The spreading type material distributor is provided with a load control system which can accurately control the material distribution amount, a position control system of the spreading type material distributor can carry out all-dimensional pouring on a mould in a platform template, and a unique sensing and pouring control system of the spreading type material distributor can carry out all-dimensional uniform material distribution. The volume of the hopper is matched with the mixing amount of a common concrete mixer, and the hopper can be butted with the original mixing equipment without gaps. The travelling speeds of a trolley and a cart of the paving type material distributor can be adjusted and controlled, and the paving type material distributor is provided with an anti-collision stopping mechanism. The system is provided with devices for overload protection, flow control and the like, so that the stable performance and stable operation of the equipment can be ensured, and the whole machine is simple to operate, safe and reliable.

The steam curing device 9 is an intelligent steam curing and capping temperature control integrated system, after the mold 14 is hung into the curing pool, the automatic capping system performs capping in a retractable door mode, and meanwhile, the automatic curing system automatically adjusts the steam flow and controls the steam curing temperature, and a temperature linear graph is generated, so that the intelligent temperature control of the steam curing is realized, and the temperature in the steam curing process is automatically acquired, controlled and recorded.

Sleeper shedder 10 includes truss outer frame component, truss outer frame component includes truss beam assembly 44, truss beam assembly 44's downside is provided with and is used for the semifinished product's of keeping in storage subassembly 45, truss beam assembly 44's downside still is provided with the drawing of patterns subassembly 46 that are used for separating mould 14 and sleeper 12, be connected with on truss beam assembly 44 and be used for carrying and overturn semifinished product's mould clamping component 47, mould clamping component 47 is located the upside of depositing subassembly 45 and can be carried semifinished product to drawing of patterns subassembly 46. Mold clamping member 47

The demolding assembly 46 comprises symmetrically arranged action pieces, wherein each action piece comprises a jacking table 48, a demolding table 49 and a detection table 50, the detection tables 50 on the two sides are arranged between the demolding tables 49 on the two sides, and the demolding tables 49 on the two sides are arranged between the jacking tables 48 on the two sides. Wherein, be provided with the first jacking piece 51 that is used for jacking up the mould on jacking platform 48, be provided with the second jacking piece 52 that is used for jacking semi-manufactured goods on the demoulding platform 49, all be provided with a plurality of detection pieces 53 that are used for detecting that mould 14 and sleeper 12 separate the completion on the detection platform 50 of both sides.

Preferably, a die pillow conveying track 54 is arranged between the detection tables 50 on the two sides, a sleeper conveying assembly 55 and a die conveying assembly 56 are arranged on the die pillow conveying track 54, and third jacking pieces 57 are arranged on the sleeper conveying assembly 55 and the die conveying assembly 56.

The end of the sleeper demoulding device 10 where the storage assembly 45 is located is a semi-finished product input end and is connected with the steam curing device 9, the end of the sleeper transportation assembly 55 is a finished product output end and is connected with the sleeper detection device 11, and the end of the mould transportation assembly 56 is a mould output end and is connected with the mould cleaning device 1.

The first jacking piece 51, the second jacking piece 52 and the third jacking piece 57 are jacking air cylinders which are jacking air cylinders. The cylinder bodies of the first jacking piece 51 and the second jacking piece 52 are fixed on the ground, and when the semi-finished sleeper jacking device works, the upper end face of the piston rod of the first jacking piece 51 is in contact with the mold, and the upper end face of the piston rod of the second jacking piece 52 is in contact with the semi-finished sleeper. The cylinder body of the third jacking member 57 on the sleeper transportation assembly 55 is fixed on the sleeper transportation assembly 55, the cylinder body of the third jacking member 57 on the mold transportation assembly 56 is fixed on the mold transportation assembly 56, and the upper end surfaces of the piston rods of the third jacking member 57 are respectively contacted with a sleeper and a mold during operation.

The demolding process of the sleeper demolding device 10 is as follows: after the semifinished products are first transported out of the steam curing device 9 by rail, they are directly transferred to the storage assembly 45, then they are held by the mold holding members 47 and transferred from the storage assembly 45 to the stripper assembly 46, during which the semifinished products are turned 180 ° over, the molds 14 being turned on the lower sleepers 12 and the molds 14 being turned on the upper sleepers 12. After reaching the position of the stripping assembly 46, the mold gripping members 47 release the semi-finished product and return to the upper side of the storage assembly 45 ready for the next delivery. The second jacking piece 52 on the demoulding table 49 continuously and quickly jacks up the semi-finished product, then the second jacking piece 52 is quickly withdrawn, the pushed-out finished product can move downwards under the action of gravity, the first jacking piece 51 on the jacking table 48 can prevent the mould 14 from continuously moving downwards, but cannot prevent the sleeper 12 from moving downwards, and the mould 14 and the sleeper 12 are separated due to inertia, so that the aim of demoulding is fulfilled. Simultaneously all there is 4 detection pieces 53 on every side detection platform 50, and detection piece 53 is pressure sensor, and after sleeper 12 on the mould 14 all breaks away from, the pressure on the pressure sensor can be close or even equal, treats 8 pressure sensor homogeneous phase differences under 4 sleeper 12 and judges that the drawing of patterns is accomplished when very little, and second jacking piece 52 stop work, first jacking piece 51 lifts mould 14 until breaking away from sleeper 12 completely. The tie transporting assembly 55 moves to the lower side of the tie 12, the third lifting member 57 on the upper side thereof lifts up and transports the tie 12 into the tie detecting device 11, after the tie 12 is transported away, the mold 14 is lowered to the position before the tie 12 is transported away, and then the mold transporting assembly 56 moves to the lower side of the mold 14, and the third lifting member 57 on the upper side thereof lifts up and transports the mold 14 into the mold cleaning device 1.

The tie detection device 11 includes a second laser image detection part having an image detection function, a tie recognition part for detecting the tie 12, and a coding part for coding. The sleeper detection device 11 is an automatic sleeper detection system, the above-mentioned components are only part of execution components in this system, utilize laser image detection technology intelligent detection sleeper overall dimension, automatic identification appearance quality and generation detection report, sleeper information that the detection is accomplished forms unique serial code and two-dimensional code, and directly print on the sleeper through automatic coding equipment.

The blow injection buckle device 13 comprises a sleeper transmission rail 35 for conveying the double-block sleepers, wherein manipulator components 36 with a movable function are arranged on two sides of the sleeper transmission rail 35, a driving assembly of the manipulator components 36 is electrically connected with a control center, the driving assembly is an electric motor, an integrated and rotatable base 37 is arranged at the upper side end of the manipulator components 36, and the base 37 can rotate relative to the manipulator components 36 at any angle. The base 37 is provided with a monitoring assembly which can monitor and position, the monitoring assembly is a 3D camera 38, the 3D camera 38 can see whether waste residues in the sleeve hole are cleaned up or not, oil is filled and the specific situation of a cover buckle cover is covered, the middle part of the camera and the middle part of the hole can be positioned, the base 37 is provided with an air blowing opening 39 connected with the air supply assembly, the base 37 is provided with an oil filling opening 40 connected with the oil supply assembly, and the base 37 is further provided with a buckle cover assembly 41 for buckling the cover on the sleeve hole cover. The upper surface of the base 37 is connected to the robot part 36, the cap unit 41 is provided on the lower surface of the base 37, and the monitoring unit, the gas blowing port 39 and the oil filling port 40 are provided on the side surface of the base 37. The air supply assembly is an air blower, the air blower is connected with the air blowing port 39 through an air pipe, the oil supply assembly is an oil supply tank, and the oil supply tank is connected with the oil filling port 40 through an oil conveying pipe.

3D camera 38, blow gas mouthful 39, oil filler point 40 and buckle closure subassembly 41 are fixed for the position of base 37, 3D camera 38 shoots the position of cover tube hole 75 at first, pass through control center processing back with positional information respectively give blow gas mouthful 39, oil filler point 40 and buckle closure subassembly 41, blow gas mouthful 39 can blow out high-speed air current, and clear away the waste residue of cover tube hole 75, carry out the oiling by oil filler point 40 to cover tube hole 75 after the waste residue is clear away and is accomplished, buckle closure subassembly 41 carries out the buckle closure operation to cover tube hole 75 after the oiling is accomplished. The control center controls the manipulator assembly 36 to run freely, and the various actuators on the base 38 are controlled by the control center, so that the device is fully automated, and the control center adopts the prior art.

Preferably, the cap assembly 41 includes a pick-up member that engages the inner bore of the cap end, the pick-up member having a through hole therein, and a press member disposed in the through hole and movable along the through hole for pressing the cap into the sleeve hole 75 in the sleeper. The input end of the pressing member is connected to a piston on a cylinder, the cylinder body of which is arranged inside the base 37. Wherein picking up the piece and picking up the pole, pick up the pole and can insert in the hole on the buckle closure, thereby reach the purpose of picking up the buckle closure, the pressing piece is the press bar, the press bar sets up in picking up the inside hole of pole, the press bar can pick up pole reciprocating motion relatively, when the buckle closure, the press bar is to having the direction removal of buckle closure, can push away the buckle closure from picking up the pole like this, the buckle closure just can be pressed on the entry of cover tube hole 75, in whole course of work, 3D camera 38 monitors and convenient location entirely.

The blowing and injecting buckle device 13 is an intelligent blowing, injecting and covering integrated equipment system, and the above-mentioned components are only part of execution components in the system. The system uses two industrial robots, two sets of 3D vision systems, 2 sets of cover screening mechanisms and other equipment, and when 4 sleepers reach the station. The robot drives the 3D camera and shoots the sleeper, discerns the XY coordinate skew and the depth information in sleeve pipe hole, and six robots snatch the lid from the lid sieve separator and place sleeve pipe hole site top, and closing device presses the lid to the sleeve pipe hole in, and the oiling system adopts high accuracy detection device (prior art), can guarantee the stable uniformity of oiling volume.

Sleeper buffer memory curing means 16 is an intelligent sleeper buffer memory maintenance equipment, adopts constant temperature, constant humidity intelligence maintenance system in buffer memory maintenance workshop, utilizes intelligent control instrument real-time regulation and control and digital display humiture, through remote terminal real time monitoring buffer memory workshop behavior, and intelligent sleeper buffer memory maintenance workshop has realized being changed to intelligent, information-based sleeper maintenance by artifical watering maintenance, improves sleeper maintenance grade.

The structure and connection relationship of parts, assemblies and components which are not described in detail in each device are all the prior art.

The control center 15 includes a start button for starting the production system and a stop button for closing the production line. The control center 15 is in intelligent control, an information integration mode of modularized embedding is adopted, the information integration mode comprises a production line intelligent control system, an MES manufacturing execution system, a PHM fault prediction and health management system, an SCADA data acquisition and monitoring control system, a sleeper automatic detection system is integrated and deeply fused, a sleeper production digital workshop is established, digitization and intelligent management and control of 'man, machine, material, method and ring' of sleeper prefabrication are preliminarily realized, equipment operation of the intelligent workshop is more efficient, process linking and conversion are smoother, information processing is more timely, the purposes of predicting and monitoring equipment states and centralized management and control of the whole process of an operator background are achieved, the equipment fault rate is reduced, the sleeper production efficiency is improved, and operating personnel are reduced. The technologies involved in intelligent control are all prior art.

The sleeper production process flow comprises the steps of cleaning a mould, detecting the mould, spraying a release agent, installing a double-block type sleeper sleeve, a stirrup and a truss, pouring concrete, performing steam curing, demoulding the sleeper, inspecting a finished product and curing the sleeper, and the sleeper production line can realize the functions of automation, intellectualization, no humanization and the like of each station according to the intelligent and unmanned construction target.

The length and width of the production workshop are 96m multiplied by 48m, a sleeper production workshop and a steel bar production workshop are arranged in the production workshop and are built through partition from the middle, the occupied land is 24m multiplied by 96m, and the workshop is built by adopting a color steel shed to form a closed space. The production process is used as a main line, the sleeper workshop is used as a center, the construction requirements of a full-automatic unmanned production line are combined, and all functional areas of raw material storage, concrete stirring, steel bar processing, sleeper production and sleeper cache workshop are arranged in a line, so that seamless connection of material transportation and production is achieved.

1. Stock of raw materials

A silo is used to store the sandstone raw material. In order to reduce environmental pollution, a closed storage bin is adopted, an atomization dust settling system is arranged at the top of the storage bin to settle dust in the storage bin, the length and width of the storage bin are 55.4m multiplied by 42.5m, 27 steel structure upright columns are arranged at the lower side of the storage bin to support, the steel structures are all 1.5m multiplied by 1.5m, embedded parts are 0.6m multiplied by 0.6m, and a secondary pouring method is adopted; simultaneously, 6 aggregate bins are arranged, namely 2 medium sand bins, 2 gravel bins with the size of 5-10mm and 2 gravel bins with the size of 10-20mm, the bins for each material are respectively qualified and 1 for inspection, the storage capacity of each bin is all carried out above 350m in a full-blown manner, and the requirement of normal production is met.

2. Concrete mixing

Concrete mixing adopts three forced mixers of HZQ120F8 type, take up an area of 20m 23.7m, be equipped with 5 powder jar (3 cement jar, 2 blending material jar, every jar storage capacity is 200 t), 2 individual water-reducing agent jar, 1 individual cistern, can satisfy the production demand of 1600 sleepers of daily production, jar body and important structure adopt the various steel sheet to build the shielding, link to each other with the workshop through steel construction transportation path, other 7 grades of sedimentation tanks of establishing simultaneously are used for depositing the recycle to the mixing station and the interior sewage recovery of workshop, simultaneously for guaranteeing the construction under the special environment condition, the other constant temperature water circulating system that sets up of cistern can be controlled the temperature automatically, reach the requirement of going up and down the temperature.

3. Processing of reinforcing bars

The steel bar production workshop is provided with a truss processing production line, a numerical control hoop bending machine, a hoop welding, a steel bar raw material storage area (12 m multiplied by 12 m), a semi-finished product and a finished product storage area (about 780 m)²) And the normal steel bar storage and processing supply requirements can be met.

4. Sleeper production

A full-automatic sleeper ring-shaped production line, an intelligent control center and a viewing channel are arranged in a sleeper production workshop.

The full-automatic sleeper ring type production line is reasonable in layout and capable of building an optimal production line through high-automation intelligent means, and the production line is divided into a demolding station, a mold cleaning station, a mold spraying demolding agent station, a sleeve pipe spiral rib installing station, a truss stirrup installing station, a concrete pouring station, an in-out cache station, a steam curing station, a kiln discharging cache station, a detection station, an oil filling capping station and a sleeper stacking station. In order to ensure the workshop environment, a transparent room is independently arranged at a release agent spraying station, and 2 times of recovery equipment is installed; the steam curing station is provided with 12 curing pools, each curing pool is 3.8m multiplied by 4m, 9 multiplied by 2 moulds can be stored, and a temperature control system is arranged to collect the curing temperature once every 10 min.

The intelligent control center and the observation channel are arranged in an overhead manner and are arranged at a position 3.8m away from the ground. The observation channel is 3m multiplied by 3.8m in width and height, is distributed in a semi-annular mode around the production line, can see corresponding stations through the channel glass curtain wall, and closely observes each station on the premise of ensuring safety.

The length, the width and the height of a workshop of the intelligent control center are respectively 24m multiplied by 12m multiplied by 3.8m, and a VR experience hall (used for construction safety 3D simulation demonstration experience), an informatization processing center (used for collecting data of raw materials, a sleeper prefabrication process, finished sleepers and the like to achieve control of sleeper prefabrication quality and traceability of sleeper prefabrication information) and a real-time monitoring center (used for monitoring the condition of a production line in real time to ensure normal production) are arranged in the workshop of the intelligent control center; the central control room and the sightseeing channel are built by high-quality wood boards, and are supported by steel structures, and the welding positions are not scalded.

4. Sleeper buffer memory

The sleeper cache workshop is secondary maintenance canopy, and its length and width is 48 mx 48m, adopts 26 steel construction stand supports, and the structural basis that every stand supported is 1.5m reinforced concrete, and the built-in fitting size is 0.4m 0.02m, adopts once to pour the shaping. The maintenance canopy can satisfy 10d sleeper memory space, and the shed roof sets up atomizing and sprays two sets of systems, and the temperature is adjusted to the accessible temperature for the automatic maintenance of sleeper buffer memory heat preservation moisturizing.

The production line is distributed by the production system, the conveying tracks among the devices are distributed by the production line, the conveying tracks are divided according to the difference between the functional areas and the stations, and the sleeper prefabricating devices are organically disassembled. The full-automatic device on each station forms a module unit, and the module units are organically interconnected, so that the operation time of installing/disassembling the device is reduced, and the cost is reduced. On the basis of device standardization, factors such as the whole function size, the installation/separation operation space and the transportation condition of the device are comprehensively considered, the device is integrated into a plurality of functional module units, and the module units are connected through functional connecting pieces to realize rapid installation/separation of the device. And finally, the module unit is used for loading, unloading, carrying, storing, transporting and the like on the basis, so that the standardization and modularization of the sleeper prefabricating device are realized.

The conveying track between the devices is a basic chain conveying track: comprises a roll shaft, a frame body, a supporting base, a driver, a positioning protective frame device, a guide rail device and the like. The conveyer is a conveyer with a roller shaft arrangement belt sprocket and power, and is mainly used for conveying empty molds or poured molds to the positions of corresponding devices.

The foregoing is illustrative of the preferred embodiments of the present invention, and it is to be understood that the invention is not limited to the precise forms disclosed herein, and that various other combinations, modifications, and environments may be resorted to, falling within the scope of the invention as defined by the appended claims. But that modifications and variations may be effected by those skilled in the art without departing from the spirit and scope of the invention, which is to be limited only by the claims appended hereto.

Claims (8)

1. Automatic, unmanned production system of two block type sleepers, including mould detection device (2), spout release agent device (3), sleeve pipe spiral muscle installation and reinspection device (4), truss stirrup installation and reinspection device (6), truss stirrup assembly quality (7), concrete pouring device (8) that have accurate cloth part (5), steam curing means (9), sleeper detection device (11), blow notes spiral shell ring knot device (13), control center (15) and sleeper buffer memory curing means (16), its characterized in that: the device also comprises a mould cleaning device (1) with a double screening function and a sleeper demoulding device (10) with a multi-directional conveying function;

the control center (15) is electrically connected with the execution components of the devices;

the sleeper demoulding device (10) is provided with a semi-finished product input end for conveying a semi-finished product into the sleeper demoulding device (10), a finished product output end for conveying a sleeper (12) into the sleeper detection device (11) and a mould output end for conveying a mould (14) into the mould cleaning device (1);

the device comprises a mould cleaning device (1), a mould detection device (2), a release agent spraying device (3), a sleeve spiral rib mounting and rechecking device (4), a truss stirrup mounting and rechecking device (6), a concrete pouring device (8), a steam curing device (9) and a sleeper demoulding device (10), which are sequentially connected to form an automatic circulating semi-finished product production line;

the device comprises a mould cleaning device (1), a mould detection device (2), a release agent spraying device (3), a sleeve spiral rib mounting and rechecking device (4), a truss stirrup mounting and rechecking device (6), a concrete pouring device (8), a steam curing device (9), a pillow demoulding device (10), a pillow detection device (11), a blowing injection buckling device (13) and a sleeper caching and curing device (16) which are sequentially connected and form a finished product production line for producing sleepers (12);

the truss stirrup installing and rechecking device (6) is connected with the output end of the truss stirrup assembling device (7).

2. The automated, unmanned production system of dual block sleepers of claim 1, further comprising: the mould cleaning device (1) comprises a carborundum sprayer (18) for cleaning the mould, the carborundum sprayer (18) is arranged on the upper side of the inner part of a sand return funnel (19), a roller way (20) for conveying the mould is arranged on the upper side of the sand return funnel (19), a sand blasting shell (21) connected with the sand return funnel (19) is arranged on the upper side of the roller way (20), a vibrating screen assembly (22) and two sand boxes (23) are arranged on the upper plane of the sand blasting shell (21), the two sand boxes (23) are respectively positioned on two sides of the vibrating screen assembly (22), the sand boxes (23) are connected with the vibrating screen assembly (22) through sand conveying packing augers (24), the input end of the vibrating screen assembly (22) is connected with a first sand return auger (25), a discharge pipe (17) for removing concrete residues is further arranged on the vibrating screen assembly (22), a second sand-returning packing auger (26) is arranged on the sand-returning hopper (19), and the first sand-returning packing auger (25) is connected with the second sand-returning packing auger (26) through a carborundum conveyer belt (27);

the emery return hopper (19) is also internally provided with an emery screen (28) for screening emery, a fixing rod (29) is arranged on the upper side of the emery screen (28), a plurality of emery spray heads (18) are arranged on the fixing rod (29), the emery spray heads (18) are also provided with a sand inlet (30), an air inlet (42) and a spray opening (43), the sand inlet (30) is connected with the sand box (23), and the air inlet (42) is connected with an air compressor on the outer side;

a dust removal pipeline (31) is further arranged on the upper plane of the sand blasting shell (21), the input end of the dust removal pipeline (31) is connected to the inside of the sand blasting shell (21), the output end of the dust removal pipeline (31) is provided with a dust removal box (32), and a filter screen rotating motor (33) used for extracting dust in the sand blasting shell (21) is arranged on the dust removal box (32);

and the first sand-returning packing auger (25), the second sand-returning packing auger (26) and the sand-returning hopper (19) are all provided with packing auger rotating motors (34) for providing power for conveying carborundum.

3. The automated, unmanned production system of dual block sleepers of claim 1, further comprising: the casing spiral rib installation and rechecking device (4) comprises a coil spring component (79) for processing spiral ribs, a casing storage component (80) for storing casings, and a casing spiral rib fastening component (81) for screwing the spiral ribs and the casings into a casing assembly, wherein the casing spiral rib fastening component (81) is arranged between the coil spring component (79) and the casing storage component (80), a casing spiral rib conveying belt (82) is arranged on the lower side of the casing spiral rib fastening component (81), a casing spiral rib sorting component (83) is arranged on the upper side of the casing spiral rib conveying belt (82) and is arranged between the casing spiral rib fastening component (81) and the casing storage component (80), and the casing is driven to move from the coil spring component (79) to the casing spiral rib sorting component (83) and is arranged between the casing spiral rib fastening component (81) and the coil spring component (79) A spiral rib mounting member (84) on the upper side of the spiral rib conveyor belt (82);

the casing spiral rib mounting and rechecking device (4) also comprises a casing assembly mounting rack (85), the sleeve component mounting rack (85) is provided with a sleeve spiral rib mounting part (87) used for moving the sleeve component from a sleeve spiral rib placing table (86) to the mould (14), a first rechecking part (88) for detecting the sleeve assembly is arranged on the sleeve spiral rib mounting part (87), a mould conveying roller way (89) for conveying the mould (14) is arranged at the lower side of the sleeve spiral rib mounting part (87), the sleeve spiral rib placing table (86) is arranged between the sleeve assembly mounting frame (85) and the sleeve spiral rib fastening part (81), the sleeve pipe spiral rib fastening part (81) is provided with a sleeve pipe assembly manipulator (90) for moving the sleeve pipe assembly from the sleeve pipe spiral rib fastening part (81) to the sleeve pipe spiral rib placing table (86).

4. The automated, unmanned production system of dual block sleepers of claim 1, further comprising: the truss stirrup assembling device (7) comprises a truss stirrup assembling part, a truss feeding part and stirrup feeding parts, wherein the truss feeding part and the stirrup feeding part are arranged on two sides of the truss stirrup assembling part;

the stirrup feeding part comprises a stirrup conveying roller way (58) for conveying stirrups and a stirrup conveying assembly (59) for transferring the stirrups from a reinforcement hopper assembly (60) to the stirrup conveying roller way (58), and the output end of the stirrup conveying roller way (58) is connected with the truss stirrup assembling part;

the truss feeding component comprises a truss feeding outer frame component (61), first truss clamping claw pieces (62) used for clamping, turning and moving the steel bar truss are symmetrically arranged on the truss feeding outer frame component (61), a truss receiving platform (63) used for supporting the steel bar truss is arranged on the lower side of the first truss clamping claw pieces (62), a truss conveying platform (64) used for conveying the truss receiving platform (63) is arranged on the lower side of the truss receiving platform (63), a movable truss storage platform (65) is arranged on the input side of the truss conveying platform (64), and an inverted triangle used for preventing the steel bar truss from deflecting and matched with the truss stirrups (74) is arranged at the upper end of the truss receiving platform (63);

the truss stirrup assembling component comprises a stirrup conveying belt (66) which is connected to the output end of the stirrup conveying roller way (58) and is used for conveying the steel stirrups, the output end of the stirrup conveying belt (66) is provided with a truss stirrup assembling outer frame (67), a second truss clamping jaw piece (68) used for clamping the steel bar truss is arranged on the truss stirrup assembling outer frame (67), the truss stirrup assembling outer frame (67) is connected with the output end of a truss conveying belt (69), the truss conveyor belt (69) is arranged opposite to the stirrup conveyor belt (66), one side of the input end of the truss conveying belt (69) is contacted with the output end of the truss conveying platform (64), a third truss clamping claw piece (70) for conveying the steel bar truss from the truss receiving platform (63) to the truss conveying belt (69) is arranged on the upper side of the truss conveying belt (69);

the truss stirrup assembling component further comprises a hook clamping piece (71) used for clamping a hook and a hook conveying belt (72) used for conveying the hook clamping piece (71), the output end of the hook conveying belt (72) is located on the lower side of the second truss clamping piece (68), and the input end of the hook conveying belt (72) is provided with a hook storage component used for storing the hook;

the truss stirrup assembling component further comprises a truss stirrup installing component (73) for installing the hook on the steel bar truss, the truss stirrup installing component (73) also installs the steel stirrup on the hook, and the hook and the steel stirrup are installed on the steel bar truss to form a truss stirrup (74);

the output end of the truss stirrup assembling device (7) is the second truss clamping piece (68), the second truss clamping piece (68) clamps the truss stirrups (74) to move on the truss stirrup assembling outer frame (67), and the truss stirrups (74) are placed into the truss stirrup installing and rechecking device (6).

5. The automated, unmanned production system of dual block sleepers of claim 1, further comprising: the concrete pouring device (8) comprises a feeding component (91) for conveying concrete from a stirring component to an accurate distributing component (5), the accurate distributing component (5) comprises a distributing machine hopper (92) with a quantitative material loading function, a plurality of weighing container assemblies (93) are arranged on the lower side of the distributing machine hopper (92), a plurality of closable first feed openings (94) are arranged at the bottom of the distributing machine hopper (92), each first feed opening (94) is correspondingly arranged right above the weighing container assembly (93), a closable second feed opening (95) is arranged on the lower side of the weighing container assembly (93), a feed opening driving assembly (96) for opening/closing the second feed opening (95) is arranged on the second feed opening (95), and outlets of the second feed openings (95) are arranged on the upper side of an inner cavity of the mold, the accurate material distribution part (5) is provided with a stirring assembly (97) for preventing concrete from being condensed, and the accurate material distribution part (5) and the feeding part (91) are both arranged on a bracket with a guide rail;

two groups of heavy container assemblies (93) are arranged on the lower side of the hopper (92) of the distributing machine, each group is provided with four heavy container assemblies (93), and the volumes of all the heavy container assemblies (93) are equal;

the concrete pouring device (8) further comprises a vibration component for tamping concrete.

6. The automated, unmanned production system of dual block sleepers of claim 1, further comprising: the sleeper demoulding device (10) comprises a truss outer frame component, the truss outer frame component comprises a truss cross beam assembly (44), a storage assembly (45) for temporarily storing semi-finished products is arranged on the lower side of the truss cross beam assembly (44), a demoulding assembly (46) for separating a mould (14) from a sleeper (12) is further arranged on the lower side of the truss cross beam assembly (44), a mould clamping component (47) for conveying and turning the semi-finished products is connected to the truss cross beam assembly (44), and the mould clamping component (47) is located on the upper side of the storage assembly (45) and can convey the semi-finished products to the demoulding assembly (46);

the demolding assembly (46) comprises symmetrically arranged action parts, each action part comprises a jacking table (48), a demolding table (49) and a detection table (50), the detection tables (50) on two sides are arranged between the demolding tables (49) on two sides, and the demolding tables (49) on two sides are arranged between the jacking tables (48) on two sides;

the device comprises a jacking table (48), a demolding table (49), a detection table (50) and a plurality of detection tables (53), wherein the jacking table (48) is provided with a first jacking piece (51) for jacking a mold, the demolding table (49) is provided with a second jacking piece (52) for jacking a semi-finished product, and the detection tables (50) on two sides are provided with a plurality of detection pieces (53) for detecting the completion of separation of the mold (14) and the sleeper (12);

a die pillow conveying track (54) is arranged between the detection tables (50) on the two sides, a sleeper conveying assembly (55) and a die conveying assembly (56) are arranged on the die pillow conveying track (54), and third jacking pieces (57) are arranged on the sleeper conveying assembly (55) and the die conveying assembly (56);

one end of the sleeper demoulding device (10) where the storage assembly (45) is located is a semi-finished product input end and is connected with the steam curing device (9), one end of the sleeper transportation assembly (55) where the sleeper transportation assembly is located is a finished product output end and is connected with the sleeper detection device (11), and one end of the mould transportation assembly (56) where the mould transportation assembly is located is a mould output end and is connected with the mould cleaning device (1);

the first jacking piece (51), the second jacking piece (52) and the third jacking piece (57) are all jacking air cylinders.

7. The automated, unmanned production system of dual block sleepers of claim 1, further comprising: the blowing injection buckling device (13) comprises a sleeper transmission rail (35) used for conveying double-block sleepers, manipulator components (36) with movement functions are arranged on two sides of the sleeper transmission rail (35), and an integrated and rotatable base (37) is arranged at the end part of the upper side of each manipulator component (36);

the base (37) is provided with a 3D camera (38) which has monitoring and can be positioned, an air blowing port (39) connected with the air supply assembly, an oil filling port (40) connected with the oil supply assembly, and a cover buckling assembly (41) for buckling and covering the sleeve hole cover;

the upper surface of the base (37) is connected with the manipulator part (36), the buckle cover assembly (41) is arranged on the lower surface of the base (37), and the 3D camera (38), the air blowing port (39) and the oil filling port (40) are all arranged on the side surface of the base (37);

the buckle cover assembly (41) comprises a picking piece matched with an inner hole at the end part of the buckle cover, a through hole is formed in the picking piece, and a pressing piece which can move along the through hole and is used for pressing the buckle cover into a sleeve hole on a sleeper is arranged in the through hole;

the input end of the pressing piece is connected with a piston on a cylinder, and the cylinder body of the cylinder is arranged inside the base (37).

8. The automated, unmanned production system of dual block sleepers of claim 1, further comprising:

the control center (15) comprises a start button for starting the production system and a stop button for closing the production line;

the mould (14) is provided with a sleeve assembly mounting position (77), a truss stirrup mounting position (78) and a mould number;

the die detection device (2) comprises a first laser image detection component with an image detection function, a die identification component for identifying a die number and a die selection component for selecting a damaged die;

the release agent spraying device (3) comprises a release agent spraying part filled with a release agent and a turning part used for turning the mold (14) to an inner cavity of the mold facing upwards;

the truss stirrup mounting and rechecking device (6) comprises a second rechecking component for detecting the truss stirrups (74) and the truss stirrup mounting positions;

the sleeper detection device (11) comprises a second laser image detection component with an image detection function, a sleeper recognition component for detecting the sleeper (12) and a coding component for coding.

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