DE212021000094U1 - Production line of double-block sleepers for high-speed railways - Google Patents

Abstract

Production line of double-block rail sleepers for high-speed railways, comprising an assembly station for spiral reinforcement, an assembly station for trusses, a concrete distribution station, a steam and maintenance station and a demolding station, wherein a transport roller is used to transport a mold, characterized in that furthermore a mold cleaning station, which with a sandblasting machine is provided for sandblasting the mold, a station for spraying mold release agent, the upper part of which is provided with a spray head for spraying the mold release agent, a lifting mechanism of the mold, which is located on the upper part of the production line for introducing the mold into the steam and maintenance station or leading it out the mold from the steam and maintenance station is provided, the mold cleaning station, the station for spraying mold release agent, the assembly station for spiral ribs and the assembly station for trusses connected to one another by roller gears nd, wherein the assembly station for trusses and the concrete distribution station are connected to one another by a lateral movement mechanism, wherein the hoist of the form is connected to the concrete distribution station, the steam and maintenance station and the demolding station, the assembly station for trusses also being connected to a processing station for steel reinforcement of the Truss and a processing station for stirrup reinforcements is connected, the assembly station for spiral reinforcement is also connected to a processing station for spiral reinforcement.

Description

TECHNICAL AREA

The present utility model relates to the technical field of the production of sleepers for high-speed railways, in particular to a production line of double-block sleepers for high-speed railways.

STATE OF THE ART

The rapid development and updating of computer technology has had profound influences on various traditional industries including the railway engineering industry. Due to the unprecedented development of computerization of the network and computer intelligence in the field of rail technology, China's modernization is also changing, which no longer only requires a large number of construction machines, but also increases the demands on the technical level of construction machines.

The demands on the intelligence and computerization of construction machinery in railway technology manifest themselves mainly in the further control of work parts. The conventional railway engineering construction machinery products are combined with high tech such as modern electronics, network information technology, computer technology, communication technology, artificial intelligence, robotics and multi-sensor fusion technology, etc., which greatly improves the technical content of the products and enables a large number of " intelligent construction machinery ”,“ robotised construction machinery ”and“ computerized construction machinery ”. This also represents the direction and trend of the future development of mechanical engineering.

The production line for 2 * 4 double-block rail sleepers usually has the peculiarities of labor-intensive and repetitive operations. Currently, most of the prefabrication of the domestic production line for 2 * 4 double-block rail sleepers is carried out in the factory in a centralized and mechanized manner. In the face of problems such as excessive labor costs and increased resource and environmental constraints, intelligent robots are being researched and developed and demonstratively used in sleeper production, so that sleeper production is converted from traditional construction to intelligent production and the intelligent upgrade of sleeper production is accelerated, which in the In line with China's industrial policy to promote structural reforms on the supply side and to promote quality improvement, efficiency improvement, modification and upgrading of the economy. Intelligent manufacturing in the threshold industry is currently still in its infancy. On the basis of the mechanized 1 × 4 production line with short form, manual operation was essentially reduced after the introduction of intelligence. However, due to the continuity and stability of the device during mass production, smart manufacturing in the threshold industry still needs optimization.

Based on the full adoption of the double block sleeper production line technology introduced in China, and relying on China's research and development strength, the 2 * 4 double block sleeper mechanized production line has developed and innovated the railroad double block sleeper prefabrication technology and equipment , thereby developing a set of unique double-block sleeper production technology, a labor-intensive production line. The grinding method is used for the construction work. During the construction work, the individual processes are linked end-to-end to form a closed-loop production mode.

CONTENT OF THE PRESENT INVENTION

The object of the present utility model is to eliminate the deficiencies in the prior art and to provide a production line of double-block sleepers for high-speed railways.

In order to achieve the above object, a production line of double-block rail sleepers for high-speed railways is created, which comprises an assembly station for spiral reinforcement, an assembly station for trusses, a concrete distribution station, a steam and maintenance station and a demolding station, with a transport roller for transporting a mold serves, characterized in that a mold cleaning station, which is provided with a sandblasting machine for sandblasting the mold, a station for spraying mold release agent, the upper part of which is provided with a spray head for spraying the mold release agent, a lifting mechanism of the mold, which is located on the upper part of the production line for introducing the mold into the steam and maintenance station or leading the mold out of the steam and maintenance station, are provided, wherein the mold cleaning station, the station for spraying mold release agent, the assembly station for spiral ribs and the assembly station ation for trusses are connected to one another by roller gears, the assembly station for trusses and the concrete distribution station by a lateral Movement mechanism are connected to each other, wherein the hoist of the form is connected to the concrete distribution station, the steam and maintenance station and the demolding station, wherein the assembly station for trusses is further connected to a processing station for steel reinforcement of the framework and a processing station for stirrup reinforcement, the assembly station for Spiral reinforcements is also connected to a processing station for spiral reinforcements.

It is preferably provided that the processing station for spiral reinforcement is used for processing a propeller, wherein the propeller comprises a sleeve and a spring, and wherein the spring is placed on the sleeve in order to form a spiral reinforcement.

It is preferably provided that the processing station for steel reinforcement of the framework is used for processing steel reinforcement of the framework, the processing station for stirrup reinforcement being used for processing stirrup reinforcement, the stirrup reinforcement being a closed ring-shaped steel reinforcement.

It is preferably provided that the assembly station for trusses is used to assemble a truss, the steel reinforcement of the truss and the stirrup reinforcement being connected to one another by steel bar hooks and being arranged in one piece in an inner chamber of the mold.

It is preferably provided that the concrete distribution station comprises an elevated track, a distribution bucket and a roller conveyor, the elevated track being arranged on the upper part of the concrete distribution station, the distribution bucket being arranged on the elevated track, the distribution bucket being displaceable along the elevated track, with the concrete distribution station on the floor the roller conveyor is arranged, wherein the roller conveyor can be raised or lowered, wherein a mold to be poured with concrete is arranged on the roller conveyor.

It is preferably provided that the concrete distribution station further comprises four vibration tables, a vibration motor being arranged on the floor of each of the vibration tables.

It is preferably provided that the lifting mechanism of the form comprises a guide rail support, a carriage, a trolley, a hanger, a lifting mechanism and an operating platform, the carriage being arranged for lateral movement above the guide rail support, the trolley being arranged for longitudinal movement on a rail above the Carriage is arranged, wherein the hanger is connected to the trolley by the lifting mechanism mounted on the trolley.

It is preferably provided that it further comprises an inspection station, the inspection station comprising an inspection platform, a measuring device, a control device, a machine vision device and a stacking station.

Compared to the state of the art, the present utility model has the following advantages: The individual stations of the sleeper prefabrication are innovated and optimized using intelligent technology, and technical support is provided through the use of a large number of high-tech and management platforms for prefabrication information with a focus on application technology of intelligent robots provided in solving problems in the production process on site, thereby improving the quality of construction and the efficiency of construction work, improving the fine management of the project, greatly reducing waste and saving the cost, so that the whole process of prefabrication of railway engineering projects is controllable and some unnecessary losses are avoided; at the same time, the problems of mixed personnel, cumbersome management, slow progress, waste of materials and low efficiency during construction work are solved, realizing intelligent and informed management of sleeper prefabrication, and maximizing resource utilization is effectively achieved.

Figure list

• 1 Figure 3 shows a flow chart of the operation of stations in accordance with the present utility model;
• 2 shows a schematic view of the structure of a roller train according to the present utility model;
• 3 shows a schematic view of the structure of the concrete distribution station according to the present utility model;
• 4th Fig. 13 shows a schematic view of the structure of the hoist of the mold according to the present utility model; and
• 5 shows a schematic view of the structure of the trolley in the hoist of the mold according to the present utility model.

List of reference symbols

1.

Elevated carriageway,

2.

Distribution bucket,

3.

Roller gear,

4th

Guide rail support,

5.

Dare,

6th

Trolley,

7,

Hangers,

8th.

Lifting mechanism.

DETAILED DESCRIPTION

In the following, the present utility model is further specified with reference to the accompanying drawings. The structure and the principle of the present utility model are very clear to a person skilled in the art. It should be understood that the specific embodiments described herein are only intended to illustrate and not limit the present invention.

Embodiment 1:

In the present utility model, a production line of double-block rail sleepers for high-speed railways is created, which comprises several stations, each of the stations having corresponding devices for operation. The specific stations are as follows:

Processing station for steel reinforcement of the framework:

A fully automatic production line for steel reinforcement of the trusses of the rail sleepers has a cold rolling mill, a CNC bending machine and a truss welding machine. First, the cold-rolled steel reinforcements are shaped into disks, each of the steel reinforcements being straightened by a straightening mechanism and brought into a predetermined position in order to form an embryonic shape of the framework made of steel reinforcements; After the primary positioning, the belts are processed in a wave-like shape on both sides and relaxed, with the wave-shaped steel reinforcements precisely fixed by a high-pressure cylinder, with the steel reinforcements being firmly welded at the specified position during positioning. Synchronous actions are carried out by a set of coupling devices for the high pressure air pumps in cooperation with a PL program of a truss welding unit. With each advance of the steel reinforcement framework, the shear force generated by the high-pressure air pump sets the uneven running length of an inclined rod into the correct position, after which the positioning and fixing is carried out again. The welding is carried out point by point and with the movement, which completes the entire welding process of the steel reinforcement framework. Then hydraulic shears are used to quantitatively cut off the truss.

Assembly and transport station for trusses:

The mature production line for welding steel reinforcement of the truss is used, and the AGV Smart Trolley is used to transport the machined steel reinforcement of the truss to the truss installation platform.

For a sleeper reinforcement based on 2 × 4 modules, a framework feed and transport system, a feed platform for stirrup reinforcements and a processing station for hooks are also provided, with a framework being automatically conveyed via a conveyor belt after its processing, with the steel reinforcement and the stirrup reinforcement of the framework the feed platform are automatically gripped and then intelligently assembled and shaped, with the assembled truss installed by accurate identification of the placement position, and with a rotatable pressure plate identified and automatically raised to compress the truss. The status / operation information of the devices is fed back in real time to a master control system, whereby a vision system is used during the installation of the truss, so that the positioning becomes more intelligent. At the same time, a new function is added to re-check the welding quality of the stirrup reinforcement and to sort out defective products in order to record the installation quality of trusses and stirrup reinforcements.

Processing station for stirrup reinforcements:

Before modification and upgrade: One person controls the CNC bending machine in order to process the stirrup reinforcements; and another person controls the resistance welding machine to perform welding operations, the welding quality being greatly influenced by human factors and the welding quality being difficult to guarantee.

After the modification and upgrade: After the bending and reshaping of the stirrup reinforcements by the CNC bending machine, welding is done automatically, with a welding workbench and tool clamping device automatically grabbing and welding the stirrup reinforcements and transferring them to the assembly station, after which the stirrup reinforcements are fixed. The welding robot automatically completes the welding process and automatically transports the workpiece onto the conveyor belt.

Mold cleaning station:

Modification option 1: Intelligent sensor and sandblasting technology is used to automatically clean the mold. The intelligent dedusting system sandblasts the mold. Thanks to the intelligent sensor system, the line body folds out to unfold the shape. A mixture of high pressure wind and emery is sprayed in the cleaning room to clean the inner surface of the mold cavity, with the floating dust and residues automatically collected in the storage device to ensure the environmentally sound hygiene of the construction site.

Modification option 2: An automatic mechanical intelligent dust collector is used to perform automatic mechanized cleaning of molds without manual cleaning tools. After the sensor-sensing mold has reached the specified position of the station, the line body folds out the mold to unfold it. The inner surface of the mold cavity is cleaned by sandblasting in the sandblasting room, with the floating dust and residues being blown into the storage device in order to ensure environmentally friendly hygiene on the construction site. The residues are recovered and environmentally friendly building is implemented.

The automatic mechanical intelligent dust collector is used to perform automatic mechanized cleaning of molds without manual cleaning tools. On the side of the original line body, a six-axis robot, a lateral movement path of the robot (with 7 axes), a force control unit, a grinding head, a control system, a dust extraction system, etc. are added. The roller gear is modified by adding a sensor-sensing system. After the sensor-sensing mold has reached the predetermined position of the station, the mold cavity is ground by the grinding head with a power control system in cooperation with the robot, while at the same time the dust extraction device sucks the dust, with the floating dust residues being blown into the storage device to guarantee the environmentally friendly hygiene of the construction site.

Station for spraying mold release agent:

The spraying is controlled by a fully automatic control system in order to realize automatic positioning of the mold, uniform spraying of mold release agent and real-time feedback of status and operation information of the devices to the master control system. The roller conveyor is also equipped with a sensor-sensing system. After the sensor-sensing mold has reached the preset position of the station, the mold release agent is sprayed evenly and without dead corners into the mold cavity in order to ensure even spraying. A release agent recovery device envelops the entire mold to ensure that the release agent does not leak and that the environment in the construction site is hygienic.

The spraying is controlled by a fully automatic control system in order to realize automatic positioning of the mold, uniform spraying of mold release agent and real-time feedback of status and operation information of the devices to the master control system. The roller conveyor is also equipped with a sensor-sensing system. After the sensor-sensing mold has reached the preset position of the station, the mold release agent is sprayed evenly and without dead corners into the mold cavity in order to ensure even spraying. An infrared detection device is also provided in order to realize an unmanned intelligent acceptance. A release agent recovery device envelops the entire mold to ensure that the release agent does not leak and that the area around the construction site is hygienic. No residual liquid escapes during the entire spraying process, which is environmentally friendly.

Assembly station for spiral reinforcement:

A manipulator is used to unload and load the case. The case is installed by means of a fully automatic case lock. A 3D vision inspection system measures the verticality and height of the installed spiral reinforcement of the sleeve, with the sleeve that does not meet the requirements being automatically adjusted. The spring is gripped by the manipulator and then transported to the assembly machine and is subjected to primary rotary printing together with the sheath; After the primary assembly is completed by the assembly machine, a coordinate transfer machine picks up the assembled components and places them in the mold cavity for final rotary printing.

The installation height and verticality of the installed spiral reinforcement are visually identified in real time. The cloud data is saved and analyzed by the algorithm to monitor the installation quality of the spiral reinforcement.

The sleeves are automatically sorted, transported, installed and automatically checked in the material container in order to generate the mounting height and verticality of the installed sleeves in real time. The cloud data is saved and analyzed by the algorithm to monitor the installation quality of the spiral reinforcement.

At the demolding station, an automatic circulation station of the positioning column, which can be dismantled from below, and a sleeve installation station are added. A sleeve installation platform is placed next to the sleeve installation station with a mechanical arm and a spiral rebar machining and forming machine added, a spiral rebar feeding system, a sleeve feeding system, a spiral rebar and sleeve mounting system, a fully automatic sleeve locking system modified and updated to Real-time feedback of status and process information from the fully automatic devices to the master control system. At the same time, a vision system is installed at the end of the manipulator of the framework, which uses intelligent algorithms to intelligently recognize defective products. The measured verticality and height of the installed spiral reinforcements of the sleeves are uploaded to the server in order to check and monitor the installation quality of the sleeves.

Assembly station for trusses:

A truss robot is used to move the truss over the form, the placement position being precisely determined by identification, the assembled truss installed, the rotatable pressure plate identified, the rotatable pressure plate automatically raised to compress the truss. At the same time it is checked whether the assembled truss is in place, the status / operation information of the devices being reported back to the master control system in real time.

Concrete distribution station:

The concrete is precisely distributed, the distribution being controlled by the sensor, with a quality measurement being made using a pouring measurement control system. A multifunctional cloth opening is used for the precise distribution to realize the precise distribution, arrangement and vibration without human intervention. The concrete is precisely distributed, the distribution being controlled by the sensor, with a quality measurement being made using a pouring measurement control system. A multifunctional cloth opening is used for the precise distribution, so that the precise distribution is realized by one person

Two placing machines are used, each placing machine having four discharge ports, each equipped with a pressure sensor and a gravity meter to accurately measure the weight of the concrete falling each time. The weight of a single slice of concrete is recorded with different degrees of break-in and is statistically evaluated using big data, with two data, namely 70% of the concrete weight of a first single mold shell and 30% of the concrete weight of a second single mold shell, recorded and combined each output of the concrete is adjusted according to the different degree of collapse. The concrete is distributed twice: the first time the concrete reaches 70% of the shell mold, it vibrates for 120 seconds and the frequency is 40 Hz; the second time the concrete is 30% of the shell, it vibrates for 120 seconds and the frequency is 50 Hz.

A proximity switch is added to the running rail of the material transport trolley, and a camera is added to detect the state of the concrete in the distribution bucket of the distribution machine. When the material transport trolley runs directly over the distribution machine, unloading begins, which enables the concrete transport to start and stop automatically.

The distributor bucket of the distributor is converted from the original flat-open type to the side-open type, which reduces the accumulation of concrete and improves the accuracy of the automatic measurement. At the same time, the nanomaterial ultraeverdry was introduced to paint the inner wall of the distribution tub in order to eliminate the problem of concrete adhesion.

Based on smart sensing and big data analysis technology, the concrete is precisely distributed, the distribution being controlled by the sensor, with quality measurement taking place using a pouring measurement control system. A specially designed multifunctional cloth opening is used for the precise distribution in order to realize the precise distribution, arrangement and vibration without human intervention. At the same time, based on big data technology, a specially developed algorithm and an intelligent feedback control system can guarantee precise distribution of the concrete.

Steam and maintenance station:

A temperature detection system, a pipeline regulating valve system, and an automatic temperature control system are used to realize optimal automatic temperature control and maintenance. The intelligent control center gives instructions on how to control a maintenance basin that requires steam curing to implement intelligent steam curing.

The intelligent temperature control system will upgrade the existing automatic steam and maintenance system to achieve intelligent steam and maintenance conditions without human manipulation. On the basis of the existing steam oven, a temperature detection system will be added to implement intelligent monitoring of the entire process, including heating, maintaining the high temperature and cooling. The temperature data is displayed in real time to ensure the best concrete setting effect and improve the quality of the sleepers.

Demolding station:

A sensor system is arranged at the unfolding station, an automatic unlocking and demolding system being used. An automatic unfolding of the 2 × 4 form, an automatic dismantling and placement of positioning bolts / pressure plates for truss reinforcement, and an automatic vibration demolding are implemented. A sensor system is provided at the unfolding station. After determining that the mold is in place, a signal is sent to the hydraulic system, which activates the hydraulic system to clamp and unfold the mold. After the mold has unfolded, the unfolding stops and a signal is sent to the hydraulic system, after which the mold is released. After the mold has been released, it rotates forward 90 °, sending a signal to a percussion hammer, after which the percussion hammer is activated. When all sleepers fall onto the roller conveyor of the platform, the fall detection platform detects that all sleepers have fallen, the tilting arm performs a reverse rotation of 90 °, whereby the mold is returned to the original position. Automatic unfolding and automatic vibration demolding of the 2 × 4 mold are implemented.

Based on intelligent sensor technology and visual control technology for mechanical arms, a sensor system is installed in the original unfolding station of the mold, and an automatic demolding system is added to realize automatic unfolding and automatic pneumatic hitting and demolding of the 2 × 4 mold.

A weighing sensor is attached to the roller conveyor of the demolding station, which detects whether all sleepers have fallen. When it is detected that all the sleepers have fallen, the form can be unfolded and the previous unfolding process is automatically locked.

Inspection station:

A visual inspection system, an appearance inspection system, an automatic coding system, a remote web monitoring display system, a reject system for defective products are used in conjunction with big data analysis and intelligent detection to provide automatic, intelligent and unmanned operation of the shape quality of the sleepers including automatic detection of shape dimensions and groove cracks, automatic detection of shape number, traceability of unique threshold code, detection data analysis, automatic upload, threshold coding and automatic QR code spraying, accurate inspection of the appearance of thresholds and the Data analysis, upload and print functions.

Based on industrial cameras and big data analysis technology, the original stacking station is relocated with the addition of a truss manipulator, a visual inspection system, an appearance inspection system, an automatic coding system, a web remote monitoring display system to enable automatic detection and stamping of threshold cracks realize, and at the same time realize the information interaction between the inspection data and the central control system as well as the production management system, thereby improving the automated and intelligent inspection, standardizing the inspection procedure, improving the inspection result and increasing the success rate of thresholds.

Stacking station for cleaning the rail sleepers:

The robot is guided by the vision system in order to automatically lift and stack the sleepers after the inspection. A handling and running system, a clamping system and a sorting and storage system for squared timber are added, the sorting and placing of the squared timber is carried out by a robot arm for sorting and placing.

The vision system is used for the automatic sorting and layered stacking of squared timber and interacts with the stacking device to stack the sleepers in layers. After it has been recognized that the threshold is in place, the six-axis robot, based on the intelligent visual recognition technology, grabs the sorted cover and visually locates the sleeve hole Detection, opens the valve to blow off the dust and injects the oil and covers the lid. This upgraded the traditional manual oil injection and capping process to the unmanned and intelligent process, improving the accuracy and precision of the oil injection and capping.

A stamping machine for sleepers and a stacking device for sleeper bars are provided in the stacking station at the end of the transport machine. Automated and intelligent standard operations save manual intervention and improve the threshold quality.

The robot is guided by the vision system in order to automatically lift and stack the sleepers after the inspection. A handling and running system, a clamping system, a sorting and storage system for wood blocks and a weighing sensor system are added, with the automatic handling and stacking of the sleepers being made possible by means of a handling system for sleepers and the data upload being implemented.

Case cleaning and closure station

Two manipulators are used. The front end of the manipulator is equipped with an air nozzle, an oil injection nozzle and a lid receiving device. The visual inspection system enables precise positioning. The two manipulators complete the dust removal and oil filling. Based on industrial cameras and big data analysis technology, the original stacking station is relocated, whereby two vision inspection systems for six-axis robots and a web remote monitoring display system are added, whereby the cleaning of the pre-embedded sleeves is realized, whereby after cleaning the Cover is installed to protect the sleeves.

Transport station for sleepers

The transport route is fixed and the AGV trolley is used to move the sleepers. When transporting the sleepers, the traditional transport mode, in which the forklift is manually controlled, is intelligently upgraded, whereby an AGV trolley is used, so that the unmanned transport of the logistics system of the production workshop is realized. At the same time, based on infrared sensor technology, the intelligent positioning, recording and disposition of AGV trolleys are implemented, whereby the AGV trolley is automatically offset to the specified position after calculations, which improves the safety factor of transporting the sleepers.

Secondary maintenance station for sleepers:

A waterway is arranged above a workshop for water maintenance, wherein an intelligent maintenance control cabinet is arranged, wherein in the workshop for water maintenance, temperature and humidity detection devices are provided at a distance, with a corresponding temperature and humidity being preset in advance. If the ambient temperature does not match one of the preset temperature and preset humidity, the control cabinet will automatically control the solenoid valve for spraying maintenance.

After the sleepers have been introduced into the warehouse, the system automatically activates the spraying maintenance system, the temperature and humidity are automatically controlled by sensors, the intelligent processing system determining the order of the sleepers from the warehouse by controlling the maintenance time.

Lateral movement mechanism:

At the pick-up position of the end of the roller path, the empty form is picked up, the accessories of which are mounted. The empty mold is transported to a mold ejection position that corresponds to two vibrating tables. The trolley used to transport the molds sideways runs along the guide rails. A position sensor for positioning is arranged at each of three workstations. With the automatic control system, when the carriage reaches a fixed position, the transport mechanism starts moving the mold automatically. After the conveyor has picked up an empty mold at the mold ejection position of the vibrating table, the carriage used to transport the molds laterally moves back to the pickup position at the end of the roller path. The lateral movement trolley is also provided with a safety device, an acoustic and visual alarm being enabled via an infrared proximity switch.

Central tax system:

A central control chamber is provided, the workshop production as a whole being controlled by the central control chamber, the data of the devices on the production line being extracted and then uploaded and remotely controlled. The central control chamber coordinates and controls the pace of operation of the individual stations, whereby a web system can be used to remotely monitor the operating status of the devices and to display the operating time and other conditions of the individual stations, with a health curve set, to the Monitor and assess operations in the production line in real time.

The information from the railway technology management platform and the information from the project productions are integrated into the central control chamber, which facilitates the overall management and coordination of sleeper production.

Through a remote monitoring system, an MES system, a PHM system, a SCADA system, a full life cycle system of thresholds, etc., functions such as intelligent control, monitoring, management and early warning of factory, personnel, materials, device and product quality are realized. The central control chamber centrally controls the start and stop process of the entire production line, and extracts the data upload and remote control functions of all devices on the production line. The central control chamber coordinates the control of the pace of the individual stations with the operational control, whereby a web system can be used to monitor the operational status of the devices remotely and to display the time consumption, the operational time and other states of the individual stations, wherein the operation of the production line is monitored in real time, with a health curve set to judge the operating conditions of the devices depending on the monitoring results in real time. The monitoring, the collection and the analysis of information of the complete life cycle of the sleeper production are realized, whereby a holographic sleeper field is created.

Building a virtual twin factory using simulation technology:

1. (1) Gesamte Kinematik-Simulation: die Interferenz-Probe von einer gesamten Bewegung, die Berechnung des Sicherheitsbereichs der Drehung von großen Vorrichtungen, die Einschätzung des gesamten Produktionstempos und der Effizienz, ergänzende Effizienzstatistik für Notfallpläne.
2. (2) Simulation von lokalen Parametern: das Leistungsverhalten des Hydrauliksystems zur Materialverteilung, Filtersteuerung der Vibrationsfrequenz, Start-Stopp-Antrieb der Kettenübertragung, Bahnplanung für lokale Roboter zum genauen Greifen, Festigkeitsanalyse der fertigen Schwellen usw.

An overall model of the threshold field is created in the control center, and after the start-up of the smart factory, simulation analyzes are carried out for various working conditions, predicting the overall performance of the device and products, thereby improving the design of production lines, improving device performance and product quality is. The virtual twin factory is applied in two aspects:

1. (1) Overall kinematics simulation: the interference sample of an entire movement, the calculation of the safety range of the rotation of large devices, the assessment of the overall production speed and efficiency, additional efficiency statistics for emergency plans.
2. (2) Simulation of local parameters: the performance of the hydraulic system for material distribution, filter control of the vibration frequency, start-stop drive of the chain transmission, path planning for local robots for precise gripping, strength analysis of the finished sleepers, etc.

Embodiment 2: The production process of the production line according to the present utility model has the following steps:

Step 1: The mold is transported from the roller conveyor to the mold cleaning station. The mold cleaning device consists of a folding mechanism, a conveyor mechanism of the roller conveyor and a sandblasting machine. The mold, which is conveyed by the conveyor line of the roller and is in place, is rotated 180 degrees by the folding mechanism and placed on another conveyor line of the roller. The folding is driven by a frequency-braked motor so that a slow rotation is realized. The form folded on the line body is conveyed to the sandblasting machine for sandblasting, and after cleaning is completed it is conveyed to the unfolded position and waits for a return.

Suction sandblasting is used. That is, the compressed air flows at high speed in the spray gun and thus creates a negative pressure in order to create an ejection effect, whereby the abrasive in the sand separator tank is sucked through the sand pipe into the spray gun and then together with the compressed air flow from the nozzle at high speed onto the Surface of the workpiece is shot so that the purpose of sandblasting and cleaning is achieved. At the start of operation, compressed air and sand are injected as they mix so that the compressed air can be fully utilized, with the air flow and sand flow being easy to adjust to achieve an ideal mixing ratio and high cleaning performance. The sandblasting device uses a two-in-one mode in which sandblasting and dust collection are combined and, in cooperation with the central dust collection mechanism, enables a dust-free operation of an automated station to realize mold cleaning within 1/4 mold length.

Step 2: The mold is conveyed through the roller conveyor to the demolding station. The automatic spraying device for mold release agent consists of a servo deceleration motor, a supporting framework, an automatic induction device and a nozzle, etc.

In order to improve work efficiency, an automatic spray mechanism for mold release agent is used, whereby with the use of a one-way light barrier, the position of the mold can be quickly localized to ensure that the mold release agent is sprayed evenly onto the inner wall of the mold cavity. Spraying is done together with walking. Walking is precisely controlled by a servo delay motor.

Step 3: The mold is conveyed from the roller conveyor to the assembly station for spiral reinforcement. The assembly line consists of the following parts: a spring machine, a robot, an assembly system for spiral reinforcement of the sleeve, an intermediate storage table for finished products and an installation system for spiral reinforcement of the sleeve.

The spiral reinforcement is manufactured on site and gripped by industrial robots and then placed on the pre-embedded sleeve, the pre-embedded sleeve and spiral reinforcement being assembled into one piece, with the assembled pre-embedded sleeve conveyed to the installation position, with a three-dimensional coordinate system based on the door bracket is created, whereby by fixing the mold at the corresponding station it is practical to facilitate the positioning of the position of the pre-embedded sleeve and the position of the positioning shaft and to grip the pre-embedded sleeve. The position of the positioning shaft is localized for assembly by screwing it in. During the installation process, the appropriate torque, number of revolutions, time and lowered height are controlled. Several conditions are restricted to ensure installation accuracy and quality. The post-installation height should be checked to verify that the installation of the pre-embedded sleeve meets the installation requirements.

Step 4: The mold is transported from the roller conveyor to the assembly station for trusses. The automatic steel reinforcement assembling and installing device is composed of an automatic feeding mechanism for trusses, a separating mechanism for trusses, a transferring mechanism for trusses, an automatic feeding mechanism for stirrup reinforcement, a CNC hook machine, a assembling device of hooks gripped by the robot, a three-axis transmission device, an automatic welding production line for trusses, an automatic processing device for stirrup reinforcement, etc.

Automatic feeding of the trusses: The welding production line for trusses transports a processed truss from the line body to the separating mechanism for trusses in order to feed a single truss.

Separating the trusses: When a truss is moved from the supply chain line to a predetermined position, the truss is dismantled by the clamping device and folded out, after which it is placed on the trolley for transport.

Transfer of the trusses: The truss is transferred to a specified position by the trolley. After the sensor detects that the truss is in place, the Z-axis clamp moves down to grip the truss. This clamp places the truss on the trolley for transporting the truss, which is moved to the next station for assembly.

Automatic feeding of stirrup reinforcements: The stirrup reinforcements welded by the robot are placed on the assembly line, whereby the assembly line automatically feeds in a single stirrup reinforcement.

Clamping the hooks by the robot: The robot is used to form a clamping device that clamps the hooks of the CNC hook machine. Retraction of the truss into the mold cavity: The assembled truss is placed in the mold cavity. Finally, the pressure plate is clamped by the pressure plate rotating cylinder and rotated by 90 ° in order to fix the position of the steel reinforcement. The pressure plate rotating cylinder releases the pressure plate while the steel rebar clamp returns to the installation platform position, completing a steel rebar installation cycle.

Step 5: The mold is conveyed by the roller conveyor to the side moving mechanism. The lateral movement mechanism consists of a laterally movable roller conveyor, a motor and laterally movable steel rails.

Step 6: The form is conveyed to the concrete distribution station by the lateral movement mechanism. The feed section of the concrete distribution station consists of an elevated track, a distribution bucket, a deceleration motor, a hydraulic station and two vibration motors, the distribution bucket being controlled by two deceleration motors so that it runs on the track. The driving speed of the distribution machine is controlled by a frequency converter and a potentiometer. The opening and closing of the door of the distribution bucket are controlled by the hydraulic system. The unloading of the distribution bucket is controlled by a spiral system. The vibration motor facilitates unloading. The main purpose of the distribution section is to fill the mixed concrete into the mold.

The vibrating section consists of four vibrating tables and a liftable roller conveyor. A vibration motor is located under each vibrating table to control the vibration of the vibrating table. The lifting of the roller conveyor is controlled by an airbag. The vibrating section is mainly used to shake the concrete in the mold and remove the concrete bubbles.

Step 7: The mold is lifted to the steam and maintenance station. The processes that include a two-hour standstill, two-hour heating, eight-hour constant temperature and two-hour cooling can be carried out without manual control. The steam inlet is controlled automatically, with intelligent monitoring of the entire process, with real-time display of the temperature in the furnace to ensure that the strength of the sleeper meets the design requirements.

Step 8: After the steaming maintenance has been completed, the mold is transferred to the unfolding and demolding station by the lifting mechanism of the mold. The shape of the double-block rail sleeper is unfolded by 180 ° by means of a folding and demolding machine, after which the sleeper is demolded. The shape of the double-block rail sleeper is then folded out reversed by 180 ° and then conveyed to the original roller conveyor. The sleeper is conveyed by the roller conveyor for transferring the sleeper to the inspection station. The empty mold is conveyed by the roller conveyor for transferring the mold to the mold cleaning station. The mold goes to the next process cycle.

Step 9: After the sleepers have entered the inspection station, it is automatically inspected by intelligent inspection device. The inspection system mainly consists of an inspection platform, a measuring device, a control device and a machine vision device. The inspection of the dimensions of the external appearance of the sleeper is mainly based on the principle of triangulation measurement using a laser, which realizes a three-dimensional modeling of the sleeper, with the dimension of the external appearance calculated in the model, which is compared with the standard dimension of the double-block rail sleeper, to assess the deviation in the dimension of the threshold structure. When inspecting the groove cracks, alcohol is sprayed onto the threshold groove and the camera detects the process of the alcohol disappearing to determine whether there is a crack in the threshold groove. The automatic coding device is connected to the inspection system. The infrared detection system for the dimension of the external appearance transmits the corresponding unique threshold number to the coding host, which is automatically sprayed onto the surface of the threshold after the inspection of the threshold by the coding device depending on the instructions. At the same time, the detection data of each threshold is linked to the two-dimensional code.

Step 10: After the inspection, the sleepers are conveyed by the trolley for transporting the sleepers to the stacking station, with all four sleepers being laid on one layer by the stacking machine, and with each stack consisting of four layers. Finally, the stacks are transported to the water maintenance area with a forklift and stored separately depending on the production time and batch.

Claims (8)

Production line of double-block rail sleepers for high-speed railways, comprising an assembly station for spiral reinforcement, an assembly station for trusses, a concrete distribution station, a steam and maintenance station and a demolding station, wherein a transport roller is used to transport a mold, characterized in that furthermore a mold cleaning station, which with a sandblasting machine is provided for sandblasting the mold, a station for spraying mold release agent, the upper part of which is provided with a spray head for spraying the mold release agent, a lifting mechanism of the mold, which is located on the upper part of the production line for introducing the mold into the steam and maintenance station or leading it out the mold from the steam and maintenance station is provided, the mold cleaning station, the station for spraying mold release agent, the assembly station for spiral ribs and the assembly station for trusses connected to one another by roller gears s ind, wherein the assembly station for trusses and the concrete distribution station are connected to one another by a lateral movement mechanism, the lifting mechanism of the form being connected to the concrete distribution station, the steam and maintenance station and the demolding station, the assembly station for trusses also being connected to a processing station for steel reinforcement of the Truss and a processing station for stirrup reinforcements is connected, the assembly station for spiral reinforcement is also connected to a processing station for spiral reinforcement. Production line of double-block sleepers for high-speed railways according to Claim 1 , characterized in that the processing station for spiral reinforcement is used for processing a propeller, the Propeller comprises a sleeve and a spring, and wherein the spring is fitted onto the sleeve to form a spiral reinforcement. Production line of double-block sleepers for high-speed railways according to Claim 1 , characterized in that the processing station for steel reinforcement of the framework is used for processing a steel reinforcement of the framework, the processing station for stirrup reinforcement being used for processing a stirrup reinforcement, the stirrup reinforcement being a closed ring-shaped steel reinforcement. Production line of double-block sleepers for high-speed railways according to Claim 1 or 3 , characterized in that the assembly station for trusses is used for assembling a truss, the steel reinforcement of the truss and the stirrup reinforcement being connected to one another by steel bar hooks and being arranged in one piece in an inner chamber of the mold. Production line of double-block sleepers for high-speed railways according to Claim 1 , characterized in that the concrete distribution station comprises an elevated track, a distribution bucket and a roller conveyor, the elevated track being arranged on the upper part of the concrete distribution station, the distribution bucket being arranged on the elevated track, the distribution bucket being displaceable along the elevated track, with the concrete distribution station on the floor the roller conveyor is arranged, wherein the roller conveyor can be raised or lowered, wherein a mold to be poured with concrete is arranged on the roller conveyor. Production line of double-block sleepers for high-speed railways according to Claim 5 , characterized in that the concrete placing station further comprises four vibrating tables, wherein a vibrating motor is arranged at the bottom of each of the vibrating tables. Production line of double-block sleepers for high-speed railways according to Claim 1 , characterized in that the hoist of the mold comprises a guide rail support, a carriage, a trolley, a hanger, a lifting mechanism and an operating platform, the carriage being arranged for lateral movement above the guide rail support, the trolley being arranged for longitudinal movement on a rail above the Carriage is arranged, wherein the hanger is connected to the trolley by the lifting mechanism mounted on the trolley. Production line of double-block sleepers for high-speed railways according to Claim 1 , characterized in that it further comprises an inspection station, wherein the inspection station comprises an inspection platform, a measuring device, a control device, a machine vision device and a stacking station.

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