EP1511606B1 - Method and device for the production of a precise concrete prefabricated part - Google Patents

Abstract

With a method for the production of a precise prefabricated concrete part, especially in the form of a sleeper or a plate for a fixed track for rail-guided vehicles, the prefabricated concrete part is ground at the functionally relevant points to the predetermined size by means of a grooved roller. The device for this is a grinding machine with a grooved roller to grind the prefabricated concrete part at functionally relevant points to a predetermined size. The grooved roller is made of a wear resistant material, especially silicon carbide.

Description

The present invention relates to a method for producing a precise precast concrete part, in particular in the form of a threshold or a slab for a fixed track for rail-guided vehicles and a corresponding device for producing a precise precast concrete part.

For example, solid roadways for rail-guided vehicles, wall elements, beams or supports are manufactured as precast concrete parts. In most applications of precast concrete parts, no particular precision in the dimensions of the part is required. The usual, achievable in the concrete trade tolerances are sufficient here. If other components are mounted on the precast concrete parts, which must comply with very tight tolerances, this is usually done with adjustment so that resulting from the concrete inaccuracies can be compensated. In particular, in the production of fixed carriageways, as they are known for example from DE 197 33 909 A1, rail fasteners are therefore used at the individual bases, which make the rail adjustable in several directions in order to comply with the tight tolerances between the individual rails can , In addition, elastic intermediate layers are used between the precast concrete part and the rail, which have different thicknesses to be able to position the rail head in the required height. As a result, many different thicknesses of intermediate layers are required to compensate for the relatively large tolerances of the concrete part can. The intermediate layers and the adjustable rail fasteners are complex in the production, assembly and storage.

From DE 197 53 705 A1 which discloses the preamble of the independent claims 1 and 13, concrete slabs are known for the formation of a fixed carriageway, wherein grooves are milled or cut into the concrete slabs . The grooves are used to hold elastically deformable profile elements, in which soft track rails are inserted. Although a more precise position and shape accuracy of the grooves can already be achieved with this method. Nevertheless, the tolerances and surface qualities achievable with the milling process are not sufficient for high-precision add-on parts such as track rails. Again, the rail must be embedded in elastically deformable profile elements, which compensate for the relatively imprecise production of the receiving groove. Object of the present invention is thus to provide a method and an apparatus with which precast concrete parts can be produced, which allow tighter than usual tolerances for attachments. It is thus the cost of manufacturing, equipment and assembly of the concrete construction site and the rails and their attachment significantly reduced.

The object is solved by the features of the independent claims.

According to the invention, in a method for producing a precise precast concrete part, in particular in the form of a threshold or a slab for a fixed carriageway for rail-guided vehicles, the precast concrete part is ground at the functionally relevant points to the predetermined level with a profiled roller. The profile roller has the negative shape of the cross section to be created, which is to have the precast concrete part at the function or relevant point (s). This is very advantageous, in particular at the support points at which rails are fastened to the precast concrete part. However, other parts, such as mounting grooves for the connection of two successive precast concrete parts can be prepared by the method according to the invention. By grinding the precast concrete part with a profile roller, it is possible to achieve very tight tolerances, the production is still very quickly and inexpensively feasible

In contrast to the customary in the prior art cutters, which process the precast concrete part, by grinding the part with a profile roller to create a much smoother and more accurate surface. On this surface can be done with tolerances, which are in the range of a few tenths of a millimeter, the attachment of rails or other precast concrete components. Especially in high-speed vehicles, this is very advantageous for a quiet and comfortable running of the rail vehicle.

Through the profile roller, the same shape can be produced at a variety of bases of the precast concrete in one operation. Support points, which are arranged one behind the other in the longitudinal direction of the precast concrete element, are ground by the feed of the profile roller along the longitudinal direction of the precast concrete without settling. As a result, a particularly fast and accurate production is possible because the profile roller and the precast concrete part are moved relative to each other without the position of the profile roller must be redetermined. Despite everything, it is also possible that the profile roller according to a predetermined program not only linear in the x-direction, but also in the y and z-direction of the precast concrete part can be moved. As a result, curves of a rail on the precast concrete part can be realized.

Advantageously, the profile roll is designed such that it is used for roughing and finishing. When roughing the precast concrete part, a larger volume is removed in one production pass. A material removal in the amount of 1 to 1.5 mm per pass has proved to be advantageous. When roughing the coarse contour of the later functionally required position is already created. If necessary, the roughing can also be done in several passes, especially if a larger amount of concrete has to be removed at the functionally relevant point. After roughing is done with the same profile roller or with a further profiled roller the functionally important place arbitrated. Here, material is removed at a height of about 1/10 - 2/10 mm. The finishing achieves a particularly fine surface, which moreover has low tolerances, so that a threshold or a plate for a solid roadway is produced, which is suitable for the highest speeds of rail-guided vehicles.

If the same profile roll is used for roughing and sizing, it is advantageous if the profile roll is dressed between roughing and sizing. Due to the large material removal during roughing, the shape of the profile roller may have been damaged. By dressing becomes the exact. Form of the profile roll restored after roughing, so that the allowable tolerance in finishing is accurately adhered to.

If the precast concrete part is hardened after concreting and before sanding by storage lasting several days, it will no longer change inadmissibly later and thus the machined part will also retain the machined dimension. If subsequently other components, such as rails mounted on the fixed track, so these are very precisely connected to the component.

In particular, solid lanes can be designed so that the functionally relevant areas are areas with relatively small dimensions, It is suitable for this purpose, for example, form the solid lane with bumps, which represent the bases for the tracks. Thus, only these interpolation points must be processed. However, other forms can also be produced by the method according to the invention. Thus, for example, contact points between two successive plates, which are to be connected to one another, are processed by the method according to the invention. The plates can thereby be positioned very accurately to each other. The same applies to any connecting elements to be installed, which are also to be used very accurately in the processed concrete with the process body. The remaining precast concrete part can be within a tolerance range, as is customary for the production of precast concrete parts. In addition, an individual precast concrete part can be produced by a corresponding processing of the functionally relevant points. It is thus possible for solid lanes, which are composed of a plurality of rectilinear panels polygonal, by machining the corresponding bases also to realize radii.

If the blank is stored in a defined manner for its processing, in particular in accordance with its later mounting position, then the ground, function-relevant points will also maintain their tolerances with respect to one another when the precast concrete part is mounted on the construction site.

If the blank for his processing stress-free, stored for example by means of load cells, so the component can be installed on the site so that the full tolerance of the component is available. When using individual bases on the component is thereby effected that only long-wave tolerances occur from base to base, which are more tolerable than short-wave tolerances. Long-wave tolerances are less disturbing in a high-speed driving operation than the short-wave tolerances, since the latter cause wear and lack of comfort.

If the current wear of the tool is taken into account in the processing of the function-relevant points, then a further measure is taken that the required nominal dimension is obtained very accurately.

Advantageously, the machined points are checked with regard to the actual and the specified dimensions in order to determine whether the component is suitable for the intended place of use. Otherwise, the component is intended for another site, reworked or destroyed again.

If the lowest point to be worked on the plate is used as the basis for the processing of the other bases of the plate, the precast concrete part can be brought by the removal of concrete in the required form with the allowable tolerances. It is not necessary in this advantageous embodiment of the invention that individual bases must be constructed with additional material. A processing of the precast concrete part is thereby carried out very quickly.

To be able to produce the precast concrete part very quickly to the finished size, it is intended to produce the blank in circulation production. For a particularly stable design of the precast concrete part is provided that fiber concrete is used.

The processing of the blank can be done either on site at the construction site as well as advantageously on a processing machine, in particular a grinding machine. The achievable accuracies are higher in this case than during on-site processing.

The object is further achieved by a device for producing a precise Betonfertelles, especially in the form of a threshold or a plate for a fixed track for rail-guided vehicles, which is a grinding machine with a profile roller. With the profile roller, the precast concrete part is ground to a predetermined extent at the functionally relevant points. According to the invention, the profile roller is made of a wear-resistant material, in particular of silicon carbide. By the grinding machine, on which a profile roller made of wear-resistant material is used, it is ensured that the profile, which with the profile roller in the precast concrete part is ground, is obtained with exceedingly low tolerances. The profile roller can be designed in different shapes to grind different shapes. This makes it possible, for example, to produce a prefabricated part for a different type of mounting rail for each one blank. This gives advantages in the production of precast concrete, which can be used universally for various types of installation. By the use of wear-resistant material for the roll profile, surprisingly, despite the high wear, a surface with a very low tolerance is obtained. In contrast to milling in known methods, a much more exact surface is obtained by grinding the precast concrete part.

Advantageously, the wear-resistant material of the profiled roller is arranged on a steel shaft. The profile roll is fastened by means of the steel shaft to a spindle of the grinding machine. After the wearable material has worn down to an acceptable level, it can be reprocessed by re-wearing material on the steel shaft.

If a dressing device can be fed to the wear-resistant material of the profile roller, then it can be ensured that the required shape of the profile roller for the finishing of the component is always exactly obtained. The transmitted to the component by means of the profile roller shape is thus maintained as desired. In addition, a certain amount is determined by the dressing, by means of which the feed path of the tool is precisely determined in order to achieve the required tolerance on the component.

A dressing device which has a diamond coating has proven particularly advantageous. The diamond coating is very resistant and thus ensures that the dressing device images the required shape of the profile roller without impermissible tolerances.

Advantageously, the profile roller has a diameter between 700 and 400 mm. As a result, peripheral speeds are achieved, which allow an exact processing of the precast concrete part.

If the device is associated with a measuring system for measuring the tool and / or the processed functionally relevant points of the precast concrete part, then the actual and the desired value of the tool and / or the precast concrete part can always be checked. Impermissible tolerances are thereby avoided.

Advantageously, the profile roller is used for roughing and finishing the precast concrete part. It is thereby a very efficient production of precast concrete achievable. When roughing the profile roller already generates the desired shape of the function relevant point, but still with an impermissible tolerance. The finishing of the precast concrete component brings the tolerance within the permissible range.

If the device has a plurality of profile rollers, a plurality of functionally relevant points can be processed simultaneously. This is particularly advantageous in the processing of a slab for a fixed lane or a threshold, since in one operation, the bases of two parallel rails can be processed. This also makes a particularly fast and cost-effective processing of the precast concrete element possible.

Figur 1

eine Draufsicht auf ein Betonfertigteil,

Figur 2

einen Querschnitt im Bereich eines Stützpunktes für eine Schiene,

Figur 3

eine erfindungsgemäße Schleifvorrichtung.

Further advantages of the invention are described in the following exemplary embodiments. It shows

FIG. 1

a top view of a precast concrete part,

FIG. 2

a cross section in the region of a support point for a rail,

FIG. 3

a grinding device according to the invention.

Figure 1 shows the representation of a plate 1, which was manufactured as precast concrete. A plurality of such plates 1 are laid side by side and form a solid track for a rail-guided vehicle. On the surface of the plate 1 1 bumps 2 are spaced apart from each other in two rows along the longitudinal side of the plate. Each hump 2 forms a support point 3 for the mounting of a rail. The bases 3 must be made with very small tolerances to each other to ensure the most straight course of the rails. Tolerances of, for example, only one tenth of a millimeter are required here.

Figure 2 shows a detailed view of a plate 1 with a rail support 3. The rail support 3 is arranged in the bump 2 as a recess. The rail support 3 in this case has a defined shape, which is similar to a trough. The trough bottom serves as a support 4. A rail 5 is arranged with the interposition of intermediate layers 6 on the support 4. The attachment of the rail 5 by means of screws 7, which are anchored in the concrete of the plate 1 by means of dowels 8 and by means of brackets 9, which are supported on the base 3 and an angled guide plate 10 and the rail 11. For the correct orientation of the rail 5 in the horizontal direction, the angle guide plates 10 between the flanks of the support point 3 and the foot of the rail 5 are arranged. By means of the Winkeiführungsplatten 10, the rail 5 is held in the desired position in the horizontal direction. The angled guide plates 10 may be standard parts, which substantially equal to each other. By the inventive exact manufacture of the shape of the bases 3 is an exchange or any use of angled guide plates 10 during the installation of a rail 5 possible.

This standardized use of angled guide plates 10 and intermediate layers 6 is created by the fact that the inner sides of the support points 3 and, if necessary, the support 4 is processed. This processing of the concrete on the sides of the trough and the trough bottom allows the exact alignment of the rail already by the production of the plate 1. The dashed line indicates that the plate 1 is first produced in the region of the bases 3 with oversize. The exact shape of the trough, which is determined by the fastening means of the rail, is generated by the grinding device according to the invention.

By processing the bases 3 with the grinding device according to the invention more or less material can be removed on the side parts of the trough and the support 4, so that the exact alignment of the rail 5 in the horizontal and vertical direction already largely by the individual design of the rail support. 3 is predetermined. By this method, it is even possible to realize radii or a polygon laying of the track solely by the processing of the bumps 2. The plates 1 are first produced by default and only individualized by grinding. As a result, a very fast and therefore cost-effective production of a plurality of plates 1 from a single mold is possible. A comparison to earlier production with assembly methods significantly faster production and installation of prefabricated panels 1 makes the use of these systems as solid lanes even more advantageous.

The shape of the support point 3 is produced in accordance with its trough cross-sectional shape transversely to the longitudinal direction of the rail 5 by a profiled roller. The profile roller, which has the desired shape in cross section corresponding to the solid line of the support point 3, grinds to the required Dispose of the concrete and prepares the base 3 on the appropriate fastening devices for the rail 5 before.

FIG. 3 shows a sketch of a grinding device according to the invention. The grinding device is designed as a portal grinder. On two bearings 16, a cross member 17 is slidably disposed in the x direction. For individual positioning of the grinding device 15, the traverse 17 are assigned two displacement carriages 18. By means of the shifting carriage 18, an exact positioning of the grinding device in the y- and z-direction is possible.

On the transfer carriage 18, a drive 19 and a pivoting device 20 is provided, which are in communication with a profile roller 21. About the drive 19, the profile roller 21 is driven. The profile roller 21 is delivered to the plate 1 by means of the portal grinder. Due to the special shape of the profile roller 21, the shape of the support point 3 is created on the hump 2 when grinding the plate 1. By a displacement of the cross member 17 in the x direction, the profile roller 21 is guided over a plurality of individual support points 3 on the plate 1 and thus created the mounting surface for the rail 5. By an appropriate control of the transfer carriage 18 in the y- and z-direction, an individual positioning of the bases 3 on the humps 2 can be made so that even a curve guide or polygon laying of the rail is possible.

In the illustration of Figure 3, various positions of the profile roller 21 are shown, which can be done by the displacement possibilities of the traverse or the transfer carriage 18 and the pivoting device 20.

For producing the dimensionally accurate support points 3, it is provided that the grinding device is moved by means of its traverse 17 one or more times substantially in the x-direction over the plate 1. In this case, the profile roller 21 is approximately up to the desired nominal dimension of the base. 3 delivered. The individual delivery steps can be relatively large. This roughing of the base 3 can thereby be done very quickly. Only at the last displacement of the crossbar 17 in the x direction over the plate 1, the feed path is set lower. This results in a very exact shaping of the base 3. In order to have a profile roller 21 available for this last operation, which corresponds as exactly as possible the desired shape, the profile roller 21 a dressing device 25 is delivered. The dressing device 25 consists of a diamond-coated dressing plate, which images the exact shape of the support point 3 in its cross section. By placing the rotating profile roller 21 on the dressing device 25, the profile roller 21, which consists of the softer material compared to the dressing device 25, adapted to the shape of the dressing device 25. In the final finishing, ie processing a layer only a few tenths of a millimeter thick on the support points 3, this cross-sectional shape of the profile roller 21 is thus imaged on the support point 3. It is thereby achieved a very precise shape.

While it was always assumed in the prior art in the processing of precast concrete that a very hard and largely wear-free tool should be used to allow an exact shaping of the precast concrete, the present invention assumes that the actual tool a relatively high Wear is subject. However, the last processing is done only when the tool has been brought into the desired shape again and possibly also measured again. Surprisingly, it has been found that this device according to the invention and the corresponding manufacturing method allows a much faster and more cost-effective production of precast concrete parts with extremely precise shaping at least in some places of the precast concrete part. This is particularly necessary for slabs of slab tracks, as for the creation of fixed lanes a very large number of plates is needed and these laid very quickly become. The previously existing time bottleneck in the production of fixed carriageways can thus be significantly improved.

The present invention is not limited to the illustrated embodiments. With the method according to the invention, it is also possible to produce other precast concrete parts which require extremely precisely dimensioned points, in particular if these points have a longitudinal extent with the same cross section, which can be ground. In addition, it is alternatively possible that the precast concrete part is moved to the grinding device and not, as in the illustrated embodiment, the grinding device with respect to a stationary plate. The creation of joints of the individual juxtaposed plates is possible with the illustrated method according to the invention. In this case, for example, the end faces of the plates are processed, which abut one another. Corresponding connecting elements can thereby be exactly positioned to connect the plates together. This is also advantageous if the plates are not laid straight but polygonal to each other. The faces of the plates 1 can also be processed accordingly in this case.

Claims (20)

1. Method for the production of a precise prefabricated concrete part, especially in form of a sleeper or plate (1) for a slab track for rail-guided vehicles, characterized in that the prefabricated concrete part is ground to the predetermined dimension by means of a grooved roller (21) at the functionally relevant points whereby the functionally relevant points are connection surfaces for add-on elements.
2. Method according to claim 1, characterized in that the grooved roller (21) is used for roughing and planing.
3. Method according to one or several of the preceding claims, characterized in that the grooved roller (21) is adjusted between roughing and planing.
4. Method according to one or several of the preceding claims, characterized in that the prefabricated concrete part is hardened by storing it for several days after pouring and before grinding.
5. Method according to one or several of the preceding claims, characterized in that the functionally relevant points are supporting points (3) or installation surfaces for the installation of the rail (5) or contact points of several prefabricated concrete parts that are processed.
6. Method according to one or several of the preceding claims, characterized in that the blank is placed in a defined position for processing, in particular corresponding to its subsequent installation position.
7. Method according to one or several of the preceding claims, characterized in that the blank is placed in position free of tension for processing.
8. Method according to one or several of the preceding claims, characterized in that the tool is measured by means of a measuring system and during the processing of the functionally relevant points the current wear of the tool is considered.
9. Method according to one or several of the preceding claims, characterized in that the processed points are controlled concerning their actual and nominal dimensions.
10. Method according to one or several of the preceding claims, characterized in that the lowest supporting point (3) of the plate (1) is used as a basis for the processing of the further supporting points (3) of the plate (1).
11. Method according to one or several of the preceding claims, characterized in that the blank is produced in rotational production and is made in particular of fiber concrete.
12. Method according to one or several of the preceding claims, characterized in that the blank is processed on a processing machine, in particular on a grinding machine (15).
13. Device for the production of a precise prefabricated concrete part, especially in form of a sleeper or a plate (1) for a slab track for rail-guided vehicles, characterized in that the device is a grinding machine (15) with a grooved roller (21) to grind the prefabricated concrete part at functionally relevant points to a predetermined dimension whereby the functionally relevant points represent connection surfaces for add-on elements and whereby -he grooved roller (21) is made of a material subject to wear, in particular silicon carbide.
14. Device according to the preceding claim, characterized in that the material able to wear out is located on a steel shaft.
15. Device according to one or several of the preceding claims, characterized in that an adjusting device (25) can be presented to the material that is able to wear out.
16. Device according to the preceding claim, characterized in that the adjusting device (25) is provided with a diamond coating.
17. Device according to one or several of the preceding claims, characterized in that the profile roller (21) has a diameter between 700 and 400 mm.
18. Device according to one or several of the preceding claims, characterized in that a measuring system to measure the tool and/or the processed functionally relevant points of the prefabricated concrete part is assigned to the device.
19. Device according to one or several of the preceding claims, characterized in that the grooved roller (21) can be used to rough and to plane the prefabricated concrete part.
20. Device according to one or several of the preceding claims, characterized in that the device has several grooved rollers (21) so that several functionally relevant points can be processed at the same time.

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