WO2019015305A1 - 先张法生产无砟轨道板的柔性流水生产线 - Google Patents

先张法生产无砟轨道板的柔性流水生产线 Download PDF

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Publication number
WO2019015305A1
WO2019015305A1 PCT/CN2018/075606 CN2018075606W WO2019015305A1 WO 2019015305 A1 WO2019015305 A1 WO 2019015305A1 CN 2018075606 W CN2018075606 W CN 2018075606W WO 2019015305 A1 WO2019015305 A1 WO 2019015305A1
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WO
WIPO (PCT)
Prior art keywords
station
mold
track
track plate
tightening
Prior art date
Application number
PCT/CN2018/075606
Other languages
English (en)
French (fr)
Inventor
王朝林
张正宁
史立
毕胜
程俊红
徐忠勇
屈鹏飞
隋斌
Original Assignee
山西高行液压股份有限公司
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Filing date
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Application filed by 山西高行液压股份有限公司 filed Critical 山西高行液压股份有限公司
Publication of WO2019015305A1 publication Critical patent/WO2019015305A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
    • B28B15/007—Plant with two or more identical shaping or moulding devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
    • B28B1/087—Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/245—Curing concrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/04—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members the elements being stressed
    • B28B23/043—Wire anchoring or tensioning means for the reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • B28B7/388—Treating surfaces of moulds, cores, or mandrels to prevent sticking with liquid material, e.g. lubricating

Definitions

  • the invention relates to a production line for a high-speed railway track plate, in particular to a flexible flow production line for producing a ballastless track plate by a pretensioning method.
  • ballastless track plates used in China's high-speed railways are affected by the route direction, terrain and other factors.
  • the same type of plate also has different design specifications.
  • the CRTSIII type is innocent and promoted by China.
  • the track plates are designed with P5600, P4856, P4925 and P3710.
  • the P5600 is the most widely used form factor.
  • the remaining specifications (application volume) are relatively small, but they are also indispensable.
  • the production method of the first Zhangfa production of ballastless track plates has gradually changed from the production method of the pit matrix pedestal to the production mode of the production line.
  • Due to the inconsistency of the specifications of the ballastless track plates it is impossible to build one for each specification.
  • Production line then it is necessary to have a certain flexibility of the production line, and it is necessary to be compatible with the equipment conditions and process technology of various specifications of ballastless track plates.
  • ballastless track boards by pipelines there are still problems in the production of ballastless track boards by pipelines: because the production line is a highly efficient production mode system, there must be technical failures or accidents such as key equipment or processes in the process of use, such as problems in a certain key link of the production line (or technology). When adjusting), it will affect the operation of the entire production line, which will affect the production cycle of the process, resulting in a decrease in output per unit time, which indirectly causes delays and stagnation of high-speed railway projects.
  • ballastless track plate Due to the production process of the ballastless track plate in the assembly line, the manufacturing process of each process node is different, the consumption time is not the same, and there are inevitably more equipment waiting conditions, resulting in wasted time; and the output of the ballastless track plate
  • the progress of the construction of high-speed rail projects is related to the demand. It is necessary to control the production schedule according to the actual demand and demand time to avoid the situation that the production is not enough or the inventory is too large and the land is occupied.
  • Another shortcoming of the prior art is that it is difficult to adapt to different terrain restrictions by using a single circular orbit. Therefore, it is necessary to find a large area of land for site selection, which often requires a large amount of farmland, especially when setting up a plant in the Qiuling Mountain area. .
  • the current production process requires a flexible flow production line that produces a ballastless track plate by pre-tensioning, which solves the problem of equipment compatibility and process compatibility caused by mold changes, avoids the problem of production stagnation caused by the cause, and adapts to the change of output.
  • the problem of how the production line is economically operated.
  • the present invention is directed to the above problems, and provides a flexible flow production line for producing a ballastless track plate by a pretensioning method.
  • the invention also solves the current terrain limitation of the application line environment, and can set the position of each station according to the actual situation.
  • the invention also provides a flexible flow production line operation method for producing a ballastless track plate by a pretensioning method.
  • a flexible flow production line for producing a ballastless track plate by a pretensioning method comprising a plurality of work stations arranged in a process sequence, a track disposed along the work station and at least one transfer track plate running on the track And/or the running trolley of the track plate mold, the rails are connected end to end to form an annular track, characterized in that at least one auxiliary track is connected to the circular track, and an operation is arranged along the auxiliary track. Station.
  • the flexible flow production line for producing a ballastless track plate according to the pretensioning method characterized in that the auxiliary track is disposed on the inner side and/or the outer side of the annular track and/or intersects with the circular track.
  • the flexible flow production line for producing a ballastless track plate by the pretensioning method characterized in that the track is a tangible physical track or an invisible ground running route for the running trolley, and each production station is in the process sequence. Walking track/route setting.
  • the flexible flow production line for producing a ballastless track plate by the pretensioning method characterized in that the annular track is provided with a cleaning mold station, a mold inspection station, a first installation embedded part and a coating release mold.
  • Agent station first steel cage in place and pre-tightening station, first tension station, insulation inspection station, first vibration pouring station, second vibration pouring station, pulling station, steam maintenance station
  • the working position and the demolding station are arranged, and the working signal detecting device installed in each station is provided with a central control room and a central control room.
  • the flexible flow production line for producing a ballastless track plate by the pretensioning method characterized in that a first outer rail is disposed, and the second outer pre-embedded component and the coating release agent station are sequentially disposed on the first outer rail.
  • the second steel cage is in place and the pre-tightening station and the second tensioning station, the second installed embedded part and the coating release agent station, the second steel cage is in place and the pre-tightening station and the second
  • the tensioning station is arranged in parallel with the first installation embedded part and the coating release agent station, the first steel cage in place and the pre-tightening station and the first tensioning station.
  • the flexible flow production line for producing a ballastless track plate by the pretensioning method characterized in that a first inner side rail, a second inner side rail and a third inner side rail are disposed, and the first inner rail is provided with a mold detecting station An adjacent unqualified mold repairing station, the first inner rail is further provided with an insulation detecting unqualified inspection area adjacent to the insulation detecting station, and the second inner rail is provided with a second tensioning station
  • the third inner rail is connected to the equipment service area.
  • the flexible flow production line for producing a ballastless track plate by the pretensioning method is characterized in that a transition station is arranged between the steaming room and the release device, and equipment maintenance is reserved between the transition station and the release device. Interval.
  • the flexible flow production line for producing a ballastless track plate by the pretensioning method is characterized in that a first intersecting track and a second intersecting track are arranged, and the second intersecting track is provided with a sealing station and a turning station.
  • the second intersecting track is in contact with a track at a position where the demolding station is located.
  • a flexible flow production line operation method for producing a ballastless track plate by a pretensioning method which is characterized by:
  • the first step the running trolley transports the empty mold to the cleaning mold station via the circular or auxiliary track, and cleans the mold to meet the requirements of the process specification;
  • the second step the cleaned mold is transported by the running trolley to the mold inspection station, and the mold testing equipment performs standardized testing, and the qualified mold enters the first installation embedded part and the coating release agent station or is placed on the second outer side.
  • the third step entering the first installation embedded part and the coating release agent station and / or the second installation of the embedded part and the mold release agent station of the qualified mold to apply the release agent and install the embedded parts;
  • Step 4 The first steel cage is placed in the circular orbit and the pre-tightening is carried out by the running trolley by the first installation of the embedded component and the mold release agent at the station where the release agent is applied and the embedded component is installed.
  • the working position when the first steel cage is in place and the pre-tightening station is in an inspection or fault state, the mold can be directly sent into the second steel cage into the position and the pre-tightening station via the second outer rail or the first intersecting rail;
  • the second installed embedded part and the mold release agent are coated with the release agent and the embedded mold is loaded by the running trolley to the second steel cage in the first outer rail and the pre-tightening station.
  • the track plate transferred out by the second installation embedded part and the coating release agent station can be directly sent into the first steel cage via the auxiliary track.
  • the pre-tightening station In place and pre-tightening station;
  • Step 5 Enter the first steel cage into the position and pre-tightening station and / or the second steel cage into the position and pre-tightening the track plate mold to carry out the steel cage into place, pre-tightening and copper rod installation;
  • Step 6 The mold for completing the first steel cage and pre-tightening work is carried by the running trolley to the first pulling station for pulling work.
  • the first pulling station When the first pulling station is in the repair or fault state, it can be The auxiliary rail enters the second tensioning station; the mold that completes the second steel cage insertion and pre-tightening work is carried by the running trolley to the second tensioning, and the second tensioning station is in repair or failure. In the state, it can be directly transferred to the first pull;
  • Step 7 The mold transported by the first pulling station and/or the second pulling station enters the insulation inspection station on the circular track to inspect the steel bar, and after being tested, it is transported by the running trolley to the circular track.
  • the eighth step the mold entering the vibrating pouring station is subjected to cloth, pouring and intermittent vibration to complete the forming of the track plate according to the setting procedure;
  • the ninth step the formed track plate and the track plate mold are transported by the running trolley to the pulling station, and the pulling surface of the track plate in the track plate mold is pulled by the pulling device;
  • the tenth step; the track plate mold and the track plate for completing the pulling operation are transported by the running trolley to the steaming room for steam curing operation;
  • the eleventh step sending the track plate and track plate mold after the steaming operation is completed to the first release station or the second release station to synchronously release the tension steel bars in the track plate;
  • the twelfth step transporting the track plate and the track plate mold after the completed steel bar is released to the demoulding station, the track plate is taken off by the demoulding device, and the die steel bar attachment is collected and transported by the steel bar transfer device;
  • the thirteenth step the mold of the track plate after demoulding enters the clearing mold station and enters the next cycle operation, and the track plate after the demoulding is transported by the running trolley to the sealing and anchoring station for sealing and anchoring operation;
  • Step 14 After the anchored track plate is transported by the running trolley to the turning device, the large surface is flipped by 180°, and then the surface of the track plate is subjected to three-dimensional size inspection, and the qualified product is put into storage.
  • the flexible flow production line operation method for producing a ballastless track plate by using a pretensioning method characterized in that: the first installation embedded part and the coating release agent station and the second installation embedded part and the coating release mold Agent station, first steel cage position and pre-tightening station and second steel cage position and pre-tightening station, first tensioning station and second tensioning station, first releasing station and
  • the equipment corresponding to the two-displacement station is provided with adjustment positions and preset process conditions that match the molds of different specifications, so as to adapt to the adjustment of the mold of the multi-standard model at any time.
  • the type of mold in the production process corresponds to the type of ballastless track plate.
  • the production line can meet the flow production of two molds at the same time, and can realize the process of non-stagnation of the production line, and replace any one of the two molds into the third specification mold mixed and line production.
  • the double-station setting ensures continuous production and ensures that the rail plate supply does not stop.
  • the mold detecting device/unqualified mold repairing area, the insulation detecting equipment/insulation detecting unqualified inspection area are inspected or reworked due to the presence of the detection, so the transport track is provided, and the reciprocating operation or docking can be performed according to the process design. .
  • the wire cage maintenance cannot pass, the wire cage needs to be detached from the mold and reworked, and the corresponding work die can be inspected by the insulation inspection unqualified inspection area - unqualified mold inspection area - mold inspection equipment - installation of embedded parts Release agent equipment - steel pre-tensioning positioning equipment - tensioning equipment - insulation detection equipment operation.
  • the installation of the pre-embedded part release agent device, the steel pre-tightening positioning device, the tensioning device, and the release device are all provided with adjustment positions and preset process conditions corresponding to different specifications of the mold.
  • one of the two-way parallel operation can be automatically/manually adjusted to the preset process condition and adjustment position, and the other way continues to run according to the production process without stopping.
  • the steel bar positioning device, the steel bar pre-tightening positioning device, and the die steel bar transfer device are also provided with a track for the operation of the small row crane device, which can realize the transportation of the steel cage hanging position mold and the mold steel bar.
  • the central control room has the function of sensing the working (or stopping) state of each station equipment, the running time of the process, the position of the running trolley, the position of the mold and the finished product of the track board.
  • the two-way duplex design improves the rapid response capability in production, and the equipment is ready for use. At the same time, it is compatible with a variety of specifications of ballastless track plate moulds to produce track plates in a co-linear operation, and can realize simultaneous production of two types of molds at the same time, which improves equipment utilization and reduces equipment investment.
  • the automated equipment is intelligently controlled by the central control room.
  • the flexible process program can adjust the operation of the production line, and it is more flexible.
  • the double-station design and the steaming module (steaming room) can be adjusted and adjusted, and the track plate output can be flexibly adjusted to match the project progress.
  • Figure 1 is a schematic view showing the arrangement of a flexible flow production line for producing a ballastless track plate
  • Figure 2 is a schematic view showing the rectangular arrangement of the flexible flow production line for producing a ballastless track plate
  • Figure 3 is a schematic view of a flexible flow production line for producing a ballastless track plate.
  • each work station is along the track of the running trolley carrying the transfer track plate and/or the track plate die, and is produced according to the track plate.
  • the process is sequentially arranged, and includes an endless track 101 connected end to end.
  • a blank double line indicates that the outer track (201, 202) and the inner track (301, 302, 303) are in contact with the circular track. , cross track (104, 105).
  • the circular rail 101 of the present invention is provided with a cleaning mold station 1, a mold inspection station 2, a first installation embedded part and a mold release agent station 4, a first steel cage insertion position and a pre-tightening.
  • Station 7 first pulling station 11, insulation inspection station 12, first vibrating pouring station 14 and second vibrating pouring station 15, pulling station 16, steaming room 17, transition station 18, A release station 19 and a demolding station 21 are provided.
  • the circular orbit of the present invention may be arranged according to the terrain condition, and may be rectangular, circular or irregular, etc., and the auxiliary track connected to the circular orbit may be flexibly set according to the terrain condition, the inner track, the outer track or the cross track. The settings are not limited by the figure. You can set one or more or only one or two of the three auxiliary tracks.
  • the corresponding working equipment is installed on each of the above stations, and the track is located at the lower part of the equipment, and the running trolley can travel from the lower part of each equipment when working. If the running trolley is matched with the precision industrial robot controlled by the center console, the running trolley will directly walk or stay along the set route on the ground, and each station will set the route along the running trolley according to the process requirements.
  • the track of the present invention includes a shaped track such as a parallel metal material track fixed to the ground, and a matching traveling carriage is mounted with a metal traveling wheel.
  • invisible track that is, the set route for the running trolley, each station is set along the center line of the walking route, the running trolley is equipped with rubber tires or other rollers, universal wheels, etc., and the running trolley is mounted with precise control.
  • the system such as an industrial robot, installs corresponding sensors at each station, and is operated by the central control room during operation. In addition, it can be installed on the ground with guide grooves, guide lines and other devices for easy handling.
  • a second mounting embedded part and a coating release agent station 5 a second steel cage in place and a pre-tightening station 8 and a second tensioning station 10 are disposed on the first outer rail 201, wherein the second mounting pre-position
  • the embedding and coating release agent station 5 is installed at an intersection of the first outer rail 201 and the second outer rail 202, and a process adjustment station 6 is further disposed at an end of the second outer rail for the second mold Waiting for preparation, running the car to stop and process redundancy during the production process.
  • the first intersecting track 104 intersects with the first inner track 301, the circular track and the first outer track 201 respectively, and at the intersection, a defective mold inspection station 3, an insulation inspection unqualified inspection station 13, and a first steel are respectively disposed.
  • a mold steel bar transfer device 22 and a steel cage seating preparation station 9 are respectively disposed at two ends of the intersecting rail, and a driving track 401 for running the small traveling device is disposed on the first intersecting rail 104, so that the steel cage hanging can be loaded Bit mold, and transfer of mold steel bars.
  • the second cross rail 105 is sequentially provided with a sealing station 23 and a turning station 24, and the track board is put into storage after being inspected by the turning station.
  • the demolding station 21 is disposed at an intersection of the second intersecting rail and the circular rail, and the inner end of the second intersecting station is in contact with the first intersecting rail, and the mold steel bar transfer device 22 is disposed at the intersection.
  • the two ends of the first inner rail 301 are respectively connected to the annular rail, and at the intersection, the mold detecting station 2 and the insulation detecting station 12 respectively, and the first inner rail is adjacent to the mold detecting station, which is a defective mold.
  • Both ends of the second inner rail 302 are also respectively connected to the circular rail, and a second releasing station 20 is disposed on the rail, and the third inner rail 303 is connected to the equipment maintenance station (maintenance area).
  • the flexible flow production line of the invention is provided with a central control room and controlled by a special programming software.
  • the central control room is provided with a central processing PLC module, and has a specific process program adapted to the flexibility of the production line; each station device and the running trolley are provided with sensors and wireless data acquisition.
  • the module, the radio frequency chip embedded in the track board, is provided with a radio frequency chip receiving module.
  • the central control room is arranged inside or outside the circular track.
  • Each station is provided with several identification sensors, displacement sensors and other related devices and is connected to the central control room by wire or wirelessly.
  • a sensor that recognizes and ensures accurate operation is also connected to the central control room on each of the operating carts.
  • the pipeline of the present invention is equipped with a device matching the function of the station, and matches a plurality of models and specifications of the track plate mold, and the equipment at each station is suspended and fixed on the ground by the bracket, and matched with a plurality of transport track plate molds and / or a mobile operating trolley of the track plate, the running trolley reciprocates or circulates along the central track, and transports the track plate mold and/or the track plate to the work station according to the track plate making process.
  • the central control room 25 realizes the control and monitoring of production equipment and process flow.
  • the type of the mold corresponds to the type of the ballastless track plate.
  • the production line satisfies the flow production of the two molds at the same time, and the production line can be replaced without the stagnation of the production line, and any one of the two types of molds can be onlinely replaced with the mold of the third specification.
  • one of the two-way parallel operation can be automatically/manually adjusted to the preset process condition and adjustment position, and the other way continues to run according to the production process without stopping.
  • a running track 401 for running the small row crane device is provided, which can realize the transportation of the steel cage hanging position and the mold steel bar.
  • the steaming room 17 is composed of 8 or more molds and a set of closed steaming modules, which can be set according to the capacity or expand the number of closed steaming modules.
  • the single-group closed steaming module is a door that can be automatically opened and closed by the central control room 25 at both ends of the track.
  • the molds that have been poured have accumulated 5 ⁇ 8 pieces, they are sent into the steaming module channel by the running trolley to automatically and uniformly close the steaming.
  • a transition station 18 is disposed between the steaming room 17 and the release station 19, and a equipment maintenance interval is reserved between the transition station 18 and the release device 19.
  • the operation method (process flow) of the pipeline according to the present invention is as follows:
  • the first step the running trolley transports the empty mold to the cleaning mold station 1 via the circular rail 101 or the auxiliary rail, and the mold is cleaned by the manual or clearing device to meet the requirements of the process specification;
  • the second step the cleaned mold is transported by the running trolley to the mold inspection station 2, and the mold testing equipment is tested according to the testing standard, and the qualified mold is entered into the first installation embedded part and the coating release agent station 4 or The second mounting embedded part and the coating release agent station 5 disposed on the second outer rail 202; the unqualified mold enters the unqualified mold repairing station 3 located on the first inner side rail 301 to be inspected or repaired, after repair Return to the mold inspection station 2 to detect again;
  • the third step entering the first installation embedded part and the mold release agent station 4 and/or the second installation embedded part and the mold release agent station 5 qualified mold application release agent and installing the embedded parts;
  • the fourth step the mold which is applied with the release agent and the embedded part on the first installation embedded part and the release agent station 4 is transported by the running trolley to the first steel cage located on the circular track and pre-positioned Tightening station 7, when the first steel cage is in place and the pre-tightening station is in an inspection or fault state, the mold can be directly fed into the second steel cage through the second outer rail 202 or the first intersecting rail 104.
  • the mold which is coated with the release agent and the embedded part is applied by the second mounting embedded part and the coating release agent station 5 is transported by the running trolley to the second steel cage located on the first outer rail 201 Bit and pre-tightening station 8, when the second steel cage is in place and the pre-tightening station is in the repair or fault state, the track plate which is transferred out through the second installation embedded part and the coating release agent station 5 station can be The auxiliary track is directly fed into the first steel cage and the pre-tightening station;
  • Step 5 Enter the first steel cage into the position and pre-tightening station 7 and / or the second steel cage into the position and the pre-tightening station 8 of the track plate mold to carry out the steel cage into place, pre-tightening and steel rod installation;
  • the sixth step the mold for completing the first steel cage and the pre-tightening station 7 is carried by the running trolley to the first pulling station 11 for pulling operation, when the first pulling station 11 is in an overhaul or fault state.
  • the second tensioning station 10 can be accessed via the auxiliary rail;
  • the mold for completing the second steel cage insertion and pre-tightening station 8 is carried by the running trolley to the second tensioning 10 for pulling operation, when the second tensioning
  • the work station can be directly transferred to the first pull 11 when it is in the repair or fault state;
  • the station equipments of the present invention are preset to adapt to the adjustment devices of different types and specifications of molds, and can be quickly converted when replacing different types and specifications of molds.
  • Step 7 The mold transported by the first pulling station and/or the second pulling station enters the insulating inspection station 12 on the circular track to inspect the steel bar, and after being tested, it is transported to the ring by the running trolley.
  • the eighth step the first vibrating pouring station 14 or the second vibrating pouring station 15 is arranged in series; the mold entering the vibrating pouring station is subjected to cloth, pouring and intermittent vibration to complete the forming of the track plate according to the setting program.
  • the ninth step the formed track plate and the track plate mold are transported from the running trolley to the pulling station 16 by the pulling device to pull the exposed surface of the track plate in the track plate mold.
  • Step 10 The track plate mold and the track plate of the finished pulling operation enter the transfer section 26, and are sent to the steaming module channel/steaming room by the running trolley for automatic unified closed steaming.
  • the eleventh step the track plate and the track plate mold after the steaming operation is completed is sent to the first release station 19 or the second release station 20 to synchronously release the tension bars in the track plate.
  • a transition station 18 is disposed between the steaming room 17 and the first stage 19, and a equipment maintenance section is reserved between the transition station 18 and the release device 19.
  • the twelfth step transporting the track plate and the track plate mold after the completion of the steel bar to the demolding station 21, the track plate is taken off by the demoulding device, and the die steel bar attachment is collected and transported by the steel bar transfer device 22.
  • the thirteenth step the demolished track plate mold enters the clearing mold station 1 and enters the next cycle operation, and the demolished track plate is transported by the running trolley to the sealing and anchoring station 23 for sealing operation.
  • Step 14 After the anchored track plate is transported by the running trolley to the turning device 24, the large surface is flipped by 180°, and then the surface of the track plate is subjected to three-dimensional size inspection, and the qualified product is put into storage.
  • the pre-embedded coating release agent device 4 when the mold of the new specification needs to be inserted, the pre-embedded coating release agent device 4, the steel bar pre-tightening positioning device 8, the tensioning device 10 are stopped from entering the mold, and the device automatically or manually corresponds to the corresponding specification mold.
  • the adjustment and process preset, the process adjustment position 6 is placed with a new specification mold prepared in advance, and is transported by the running trolley to the installation of the embedded parts to release the mold release agent station 4, thereby realizing the mixing of the two molds for production line production. .
  • the equipment corresponding to the release station will be automatically or manually adjusted and the process preset with the corresponding specification mold.
  • the track plate mold is released and mixed into the production line again. .
  • the overall operation of the production line does not need to be stagnant.
  • the two-way duplex design process has the function of interchangeability.
  • any one of the two-way dual-station process equipment can be shut down, including reducing the number of steaming module groups in the steaming room 17.
  • the production line can continue to run without stopping.
  • the track plate mold can be First installation embedded part and coating release agent station 4, second installation embedded part and coating release agent station 5, second steel cage in place and pre-tightening station 8, second tensioning station 10 And the first pull station 11 is bypassed.
  • the device of the first pulling station 11 is suspended for any reason, the device can be controlled to be lifted, so that the running trolley that is flowed out through the second tensioning station 10 can directly flow to the insulation detecting device 12.
  • the steel cage when the insulation detection is unqualified and cannot be repaired, the steel cage can be hoisted through the insulation inspection unqualified inspection station 13 into the unqualified mold maintenance station 3, and then enters the mold inspection station 2 to be detected again and enters the production. cycle.
  • the invention adopts the two-way double-station design to improve and optimize the rapid strain capability in production, and the equipment can be used. At the same time, it is compatible with a variety of specifications of ballastless track plate moulds to produce track plates in a co-linear operation, and can realize simultaneous production of two types of molds at the same time, which improves equipment utilization and reduces equipment investment.
  • the automated equipment is intelligently controlled by the central control room.
  • the flexible process program can adjust the operation of the production line, and it is more flexible.
  • the double-station design and the steaming module (steaming room) can be adjusted and adjusted, and the track plate output can be flexibly adjusted to match the project progress.

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Abstract

一种先张法生产无砟轨道板的柔性流水生产线，包括按工艺顺序设置的若干个作业工位，沿作业工位设置的轨道及运行在轨道上的至少一台转运轨道板和/或轨道板模具的运转小车，轨道首尾相接构成一环形轨道（101），设置有至少一条与环形轨道（101）相接的辅助轨道，沿辅助轨道上设置有作业工位。同时提供一种采用先张法生产无砟轨道板的柔性流水生产线运转方法。该流水生产线优化了生产中的快速应变能力，提高了设备利用率。

Description

先张法生产无砟轨道板的柔性流水生产线 技术领域
本发明涉及一种高速铁路用轨道板生产线，具体为一种先张法生产无砟轨道板的柔性流水生产线。
 背景技术
[0002] 在我国高速铁路中所使用的无砟轨道板，因受到线路走向、地形等等因素影响，同一种板型也分有不同的设计规格，例如我国自主并大力推广的CRTSIII型无砟轨道板，设计规格有P5600、P4856、P4925、P3710，其中P5600规格为应用量最多的板型，其余规格产量（应用量）相对较少，但也不可或缺。
当前先张法生产无砟轨道板的生产方式随着技术进步逐渐从地坑矩阵台座生产的方式转变为流水线生产方式生产，但因无砟轨道板规格的不统一，又无法每种规格建一条生产线，那么必然需要一种生产线具备一定的柔性，需要兼容多种规格无砟轨道板的设备条件和工艺技术方法。
采用流水线生产无砟轨道板还存在的问题有：因生产线为高效运转的生产方式系统，使用过程中必然存在重点关键设备或工艺等技术故障或事故，如生产线某一重点环节发生问题（或技术调整）时，会影响整个产线运转，会影响工艺的生产节拍，造成单位时间内产量的下降，间接造成高速铁路工程项目的延期、停滞。
因流水线生产无砟轨道板过程中，各个工艺节点的制造流程不同，消耗时间也不尽相同，必然出现较多的设备等待状况发生，造成时间浪费的问题；又因无砟轨道板的产量与高铁工程建设进度及需求相关，需按实际需求量、需求时间来控制生产进度量，以避免产量不够用或库存太大浪费占地的情况。
现有技术的另一个不足是采用单一环形轨道难以适应不同地形限制，因此建厂选址必须寻找面积较大的地形，往往要占用大量农田，特别是在丘凌山区建厂时选址非常困难。
综上所述，目前生产环节需要一种先张法生产无砟轨道板的柔性流水生产线，解决模具变化带来的设备兼容问题和工艺兼容问题、避免因故造成生产停滞的问题、适应产量变化引发的生产线如何经济运行的问题。
 技术问题
本发明针对上述问题，提供了一种先张法生产无砟轨道板的柔性流水生产线。解决现有技术的单一环形流水生产线不能同时生产不同规格轨道板及检修与发生故障时必须全线停车的问题。同时本发明还解决了目前生产线应用环境地形限制，可随实地状况设置各工位的位置。本发明还同时提供先张法生产无砟轨道板的柔性流水生产线运转方法。
 技术解决方案
一种先张法生产无砟轨道板的柔性流水生产线，包括按工艺顺序设置的若干个作业工位，沿所述作业工位设置的轨道及运行在所述轨道上的至少一台转运轨道板和/或轨道板模具的运转小车，所述的轨道首尾相接构成一环形轨道，其特征是设置有至少一条与所述环形轨道相接的辅助轨道，沿所述的辅助轨道上设置有作业工位。
所述的先张法生产无砟轨道板的柔性流水生产线，其特征是所述的辅助轨道设置于所述环形轨道的内侧和/或外侧和/或与所述环形轨道交叉设置。
所述的先张法生产无砟轨道板的柔性流水生产线，其特征是所述的轨道为有形的实体轨道或无形的供运转小车行走的地面行走路线，各生产工位按工艺顺序沿所述行走轨道/路线设置。
所述的先张法生产无砟轨道板的柔性流水生产线，其特征是所述环形轨道上按工艺顺序依次设置有清模工位，模具检测工位，第一安装预埋件与涂脱模剂工位，第一钢笼入位及预紧工位，第一张拉工位，绝缘检测工位，第一振动浇筑工位，第二振动浇筑工位，拉毛工位，蒸汽养护工位，放张工位与脱模工位，设置有中控室及连接中控室的安装于各工位的作业信号检测装置。
所述的先张法生产无砟轨道板的柔性流水生产线，其特征是设置有第一外侧轨道，所述第一外侧轨道上依次设置有第二安装预埋件与涂脱模剂工位，第二钢笼入位及预紧工位和第二张拉工位，所述的第二安装预埋件与涂脱模剂工位，第二钢笼入位及预紧工位和第二张拉工位与第一安装预埋件与涂脱模剂工位，第一钢笼入位及预紧工位和第一张拉工位并行设置。
所述的先张法生产无砟轨道板的柔性流水生产线，其特征是设置有第一内侧轨道、第二内侧轨道与第三内侧轨道，所述第一内侧轨道上设置有与模具检测工位相邻的不合格模具检修工位，所述第一内侧轨道上还设置有与绝缘检测工位相邻的绝缘检测不合格检修区,所述第二内侧轨道上设置有第二张拉工位，所述第三内侧轨道连接设备检修区。
所述的先张法生产无砟轨道板的柔性流水生产线，其特征是设所述蒸养房与放张设备间设置有过渡工位，过渡工位与放张设备间还预留有设备维修区间。
所述的先张法生产无砟轨道板的柔性流水生产线，其特征是设置有第一交叉轨道与第二交叉轨道，所述第二交叉轨道上设置有封锚工位及翻板工位，所述第二交叉轨道与脱模工位所在位置的轨道相接。
一种采用先张法生产无砟轨道板的柔性流水生产线运转方法，其特征是：
第一步： 运转小车经由环形轨道或辅助轨道将空模具托运至清模工位，将模具清理至符合工艺规范要求；
第二步： 经清理后的模具由运转小车托运至模具检测工位，由模具检测设备进行标准化检测，检测合格模具进入第一安装预埋件与涂脱模剂工位或置于第二外侧轨道上的第二安装预埋件与涂脱模剂工位；不合格者进入位于第一内侧轨道上的不合格模具检修工位待检或维修，维修后返回模具检测工位再次检测；
第三步：进入第一安装预埋件与涂脱模剂工位和/或第二安装预埋件与涂脱模剂工位的合格模具涂抹脱模剂并安装预埋件；
第四步：由第一安装预埋件与涂脱模剂工位上经涂抹脱模剂并安装预埋件的模具经运转小车托运至位于环形轨道上的第一钢笼入位及预紧工位，当第一钢笼入位及预紧工位处于检修或故障状态时该模具可经由第二外侧轨道或第一交叉轨道直接送入第二钢笼入位及预紧工位；由第二安装预埋件与涂脱模剂工位上经涂抹脱模剂并安装预埋件的模具由运转小车托运至位于第一外侧轨道上的第二钢笼入位及预紧工位，当第二钢笼入位及预紧工位处于检修或故障状态时经第二安装预埋件与涂脱模剂工位工位转出的轨道板可经由辅助轨道直接送入第一钢笼入位及预紧工位；
第五步：进入第一钢笼入位及预紧工位和/或第二钢笼入位及预紧工位的轨道板模具顺序进行钢笼入位，预紧及铜棒安装；
第六步：完成第一钢笼入位及预紧工位作业的模具由运转小车托运至第一张拉工位进行张拉作业，当第一张拉工位处于检修或故障状态时可经由辅助轨道进入第二张拉工位；完成第二钢笼入位及预紧工位作业的模具由运转小车托运至第二张拉进行张拉作业，当第二张拉工位处于检修或故障状态时可直接转运至第一张拉；
第七步：由第一张拉工位和/或第二张拉工位转运出的模具进入环形轨道上的绝缘检测工位对钢筋进行绝缘检测，经检测合格后由运转小车托运至环形轨道上第一振动浇筑工位或第二振动浇筑工位；绝缘检测不合格的模具则进入绝缘检测不合格检修区进行调整，然后返回绝缘检测工位再次检测；
第八步；进入振动浇筑工位的模具按设定程序进行布料、浇筑并同时进行间歇振动完成轨道板成型作业；
第九步：成型的轨道板暨轨道板模具由运转小车托运至拉毛工位由拉毛设备对轨道板模具内的轨道板裸露表面进行拉毛作业；
第十步；完成拉毛作业的轨道板模具暨轨道板由运转小车托运至蒸养房内进行蒸汽养护作业；
第十一步： 将蒸养作业完成后的轨道板暨轨道板模具送至第一放张工位或第二放张工位对轨道板内的张拉钢筋进行同步放作业；
第十二步：将完成钢筋同步放张后的轨道板暨轨道板模具运至脱模工位由脱模设备将轨道板脱出，模具钢棒附件由钢棒转移设备收集转运；
第十三步；脱模后的轨道板模具进入清模工位进入下一循环作业，脱模后的轨道板由运转小车托运至封锚工位进行封锚作业；
第十四步：将封锚后的轨道板由运转小车托运至翻转设备上大面翻转180°后对轨道板表面进行三维尺寸检测，合格品入库。
所述的采用先张法生产无砟轨道板的柔性流水生产线运转方法，其特征是：所述的第一安装预埋件与涂脱模剂工位与第二安装预埋件与涂脱模剂工位、第一钢笼入位及预紧工位与第二钢笼入位及预紧工位、第一张拉工位与第二张拉工位、第一放张工位与第二放张工位所对应的设备均设置有与不同规格模具匹配的调整位及预设工艺条件，以适应多规格型号模具的随时调整。
生产过程中模具种类与无砟轨道板规格种类对应。生产线可满足同时供两种模具混编进行流转生产，并可实现生产线不停滞的情况下，把两种模具中的任意一种在线更换为第三种规格的模具混编并线生产。此外，当生产线中主要设备需要检修或发生故障需要维护时，双工位设置可保证生产持续进行，确保轨道板供应不会停止。
所述模具检测设备/不合格模具检修区、绝缘检测设备/绝缘检测不合格检修区因存在检测不通过进而进行待检或返工状况，所以设置有运送轨道，可按工艺设计进行往复运行或停靠。
当绝缘检测不合格时，钢丝笼检修无法通过，钢丝笼需要拆离模具并返工，对应工作模具可依次由绝缘检测不合格检修区-不合格模具检修区-模具检测设备-安装预埋件涂脱模剂设备-钢筋预紧定位设备-张拉设备-绝缘检测设备运转实现。
安装预埋件涂脱模剂设备、钢筋预紧定位设备、张拉设备、放张设备均设置有与不同规格模具对应的调整位与预设工艺条件。当需要插入某型模具进行生产时，可对双路并线运行中的其中一路设备进行自动/手动调整至预设工艺条件及调整位，另一路继续按生产工艺不停机流转运行。
所述钢筋入位设备、钢筋预紧定位设备、模具钢棒转移设备间还设置有用于小型行吊装置运行的轨道，可实现钢筋笼吊装入位模具，和模具钢棒的转运。
所述中控室具有感知各个工位设备工作（或停止）状态、工艺运行时间、运转小车位置、模具及轨道板成品位置的功能。
 有益效果
本发明创造具有的优点和积极效果是：双路双工位设计改进优化了生产中的快速应变能力，设备可备可用。同时兼容多种规格无砟轨道板模具共线运转生产轨道板，且可实现两种规格模具同时共线生产，提高了设备利用率，减少了设备投资， 自动化的设备由中控室智能化管控，采用柔性化的工艺程序可调节生产线运行的能力，更具灵活性，双工位的设计与可增减设置的蒸养模块（蒸养房），可灵活调节轨道板产量与工程进度匹配。
 附图说明
图1是生产无砟轨道板的柔性流水生产线轨道设置示意图；
图2生产无砟轨道板的柔性流水生产线轨道矩形设置示意图；
图3是生产无砟轨道板的柔性流水生产线示意图。
图中，1-清模工位；2-模具检测工位；3-不合格模具检修工位；4-第一安装预埋件与涂脱模剂工位；5-第二安装预埋件与涂脱模剂工位；6-工艺调整工位；7-第一钢笼入位及预紧工位；8-第二钢笼入位及预紧工位；9-钢笼入位设备；10-第二张拉工位；11-第一张拉工位；12-绝缘检测工位；13-绝缘检测不合格检修工位；14-第一振动浇筑工位；15-第二振动浇筑工位；16-拉毛工位；17-蒸养房；18-过渡工位；19-第一放张工位；20-第二放张工位；21-脱模工位；22-模具钢棒转移设备；23-封锚工位；24-翻转工位；25-中控室；26-转运区间；101-环形轨道；201-第一外侧轨道；202-第二外侧轨道；301-第一内侧轨道；302-第二内侧轨道；303-第三内侧轨道；104-第一交叉轨道；105-第二交叉轨道； 401-行车轨道。
 本发明的实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本申请实施例中的附图，对本发明实施例中的技术方案作进一步描述。
图1-2所示，本发明的先张法生产无砟轨道板的柔性流水生产线，各作业工位沿承载转运轨道板和/或轨道板模具的运转小车的轨道为轴线，按轨道板生产工艺顺次设置，其包括一个首尾相接的环形轨道101，图中空白双线条表示，与所述环形轨道相接的有外侧轨道（201，202）、内侧轨道（301，302，303），交叉轨道（104，105）。
图3所示，本发明的环形轨道101上设置有清模工位1、模具检测工位2、第一安装预埋件与涂脱模剂工位4、第一钢笼入位及预紧工位7、第一张拉工位11、绝缘检测工位12、第一振动浇筑工位14和第二振动浇筑工位15、拉毛工位16、蒸养房17、过渡工位18、第一放张工位19、脱模工位21。本发明的环形轨道可根据地形状况进行设置，其可以是矩形、圆形或不规则形状等，与环形轨道相接的辅助轨道可根据地形状况进行灵活设置，内侧轨道、外侧轨道或交叉轨道的设置不受图中所限，可以设置一条或多条或者只设三种辅助轨道中的一种或两种。
上述各工位上安装相应作业设备，轨道位于设备下部，各设备工作时运转小车可从其下部穿行。如果运转小车配合精密工业机器人由中控台控制，则运转小车直接在地面沿设定路线行走或停留，各工位按工艺要求沿运转小车设定路线设置。
本发明的轨道包括有形的轨道如固定在地面的平行金属材料轨道，与其匹配的运转小车上安装有金属行走轮。或无形的轨道，即属于设定的供运转小车行走的路线，各工位沿该行走路线的中心线设置，运转小车安装橡胶轮胎或其它滚轮、万向轮等，运转小车上安装有精密控制系统，如工业机器人，各工位安装相应的传感器，运行时由中控室控制进行作业。此外还可在地面安装导向槽、导向线等装置方便操控。
在第一外侧轨道201上设置有第二安装预埋件与涂脱模剂工位5、第二钢笼入位及预紧工位8和第二张拉工位10，其中第二安装预埋件与涂脱模剂工位5安装在第一外侧轨道201与第二外侧轨道202的交叉位置，在第二外侧轨道的端点处还设置有工艺调整工位6，用于第二种模具的待入准备、运转小车停靠及生产过程中的工艺冗余设置等。
第一交叉轨道104与第一内侧轨道301、环形轨道和第一外侧轨道201分别交叉，在交叉点上分别设置有不合格模具检修工位3、绝缘检测不合格检修工位13、第一钢笼入位及预紧工位7、第二钢笼入位及预紧工位8。在该交叉轨道两端分别设置有模具钢棒转移设备22与钢笼入位准备工位9，在第一交叉轨道104上设置有用于小型行车装置运行的行车轨道401，可实现钢筋笼吊装入位模具，和模具钢棒的转运。
第二交叉轨道105上依次设置有封锚工位23与翻转工位24，轨道板在翻转工位经检测合格后入库待用。脱模工位21设置在第二交叉轨道与环形轨道交叉点上，第二交叉工位的内端处与第一交叉轨道相接，模具钢棒转移设备22设置在该相交点。
第一内侧轨道301的两端分别与环形轨道相接，在交汇处分别是模具检测工位2与绝缘检测工位12，在第一内侧轨道上与模具检测工位相邻的是不合格模具检修工位3及与绝缘检测工位相邻的绝缘检测不合格检修工位13。
第二内侧轨道302的两端同样分别与环形轨道相接，在该轨道上设置有第二放张工位20，第三内侧轨道303连接设备维修工位（维修区）。
本发明的柔性流水生产线设置中控室并采用专用编程软件控制运行，中控室设置有中央处理PLC模块，具有适应生产线柔性化的特定工艺程序；各个工位设备、运转小车设置有传感器及无线数据采集模块，轨道板内埋的射频芯片，设置有射频芯片接受模块。从而实现中控室对生产线的监控与控制。
中控室设置在环形轨道内侧或外侧。各工位均设置若干个识别传感器、位移传感器等相关装置并与中控室通过有线或无线连接。各运转小车上同样设置各种能够识别并保证其精确运行的传感器与中控室相连。
本发明的流水线配置有与所述工位功能匹配的设备，匹配多种型号、规格的轨道板模具，各工位上的设备由支架悬置固定于地表，匹配有若干台运送轨道板模具和/或轨道板的移动式运转小车，所述运转小车沿中心轨道往复或循环移动，依据轨道板制作工序将轨道板模具和/或轨道板转运至作业工位。中控室25实现生产装备及工艺流程的控制与监控。
所述的模具种类与无砟轨道板规格种类对应。且生产线满足同时供两种模具混编进行流转生产，并可实现生产线不停滞的情况下，把两种模具中的任意一种在线更换为第三种规格的模具混编并线生产。当需要插入某型模具进行生产时，可对双路并线运行中的其中一路设备进行自动/手动调整至预设工艺条件及调整位，另一路继续按生产工艺不停机流转运行。
设置有用于小型行吊装置运行的行车轨道401，可实现钢筋笼吊装入位、模具钢棒的转运。
蒸养房17为8块或多块模具为一组的封闭蒸养模块组成，可依据产能设置或扩展若干数量封闭蒸养模块。
单组封闭蒸养模块为轨道两端可由中控室25自动开启关闭的门，当已浇筑完成的模具累积5~8块时，由运转小车送入蒸养模块通道内进行自动统一封闭蒸养。
所述蒸养房17与放张工位19间设置有过渡工位18，过渡工位18与放张设备19间还预留有设备维修区间。
本发明所述流水线的运转方法（工艺流程）如下：
第一步：运转小车经由环形轨道101或辅助轨道将空模具运至清模工位1，由人工或清模装置将模具清理至符合工艺规范要求；
第二步： 经清理后的模具由运转小车托运至模具检测工位2，由模具检测设备按检测标准进行检测，检测合格的模具进入第一安装预埋件与涂脱模剂工位4或置于第二外侧轨道202上的第二安装预埋件与涂脱模剂工位5；不合格模具进入位于第一内侧轨道301上的不合格模具检修工位3待检或维修，维修后返回模具检测工位2再次检测；
第三步：进入第一安装预埋件与涂脱模剂工位4和/或第二安装预埋件与涂脱模剂工位5的合格模具涂抹脱模剂并安装预埋件；
第四步：在第一安装预埋件与涂脱模剂工位4上经涂抹脱模剂并安装预埋件的模具由运转小车托运至位于环形轨道上的第一钢笼入位及预紧工位7，当第一钢笼入位及预紧工位处于检修或故障状态时该模具可经由第二外侧轨道202或第一交叉轨道104直接送入第二钢笼入位及预紧工位8；由第二安装预埋件与涂脱模剂工位5上经涂抹脱模剂并安装预埋件的模具由运转小车托运至位于第一外侧轨道201上的第二钢笼入位及预紧工位8，当第二钢笼入位及预紧工位处于检修或故障状态时经第二安装预埋件与涂脱模剂工位5工位转出的轨道板可经由辅助轨道直接送入第一钢笼入位及预紧工位；
第五步：进入第一钢笼入位及预紧工位7和/或第二钢笼入位及预紧工位8的轨道板模具顺序进行钢笼入位、预紧及钢棒安装；
第六步：完成第一钢笼入位及预紧工位7作业的模具由运转小车托运至第一张拉工位11进行张拉作业，当第一张拉工位11处于检修或故障状态时可经由辅助轨道进入第二张拉工位10；完成第二钢笼入位及预紧工位8作业的模具由运转小车托运至第二张拉10进行张拉作业，当第二张拉工位处于检修或故障状态时可直接转运至第一张拉11；
上述第四、五和第六步中可根据工程需要，同时安排两种不同型号、规格的模具进行生产，更换模具时另一相同工位的生产水受影响。本发明所述的各工位设备预设适应不同型号、规格模具的调整装置，更换不同型号、规格模具时可迅速转换设置。
第七步：由第一张拉工位和/或第二张拉工位转运出的模具进入环形轨道上的绝缘检测工位12对钢筋进行绝缘检测，经检测合格后由运转小车托运至环形轨道上第一振动浇筑工位14或第二振动浇筑工位15；绝缘检测不合格的模具则进入绝缘检测不合格检修区13进行调整，然后返回绝缘检测工位12再次检测。
第八步；第一振动浇筑工位14或第二振动浇筑工位15串行设置；进入振动浇筑工位的模具按设定程序进行布料、浇筑并同时进行间歇振动完成轨道板成型作业。
第九步：成型的轨道板暨轨道板模具由运转小车托运至拉毛工位16由拉毛设备对轨道板模具内的轨道板裸露表面进行拉毛作业。
第十步；完成拉毛作业的轨道板模具暨轨道板进入转运区间26，由运转小车将其送入蒸养模块通道/蒸养房内进行自动统一封闭蒸养。
第十一步： 将蒸养作业完成后的轨道板暨轨道板模具送至第一放张工位19或第二放张工位20对轨道板内的张拉钢筋进行同步放作业。
在蒸养房17与第一放张工位19之间设置有过渡工位18，过渡工位18与放张设备19间还预留有设备维修区间。
第十二步：将完成钢筋同步放张后的轨道板暨轨道板模具运至脱模工位21由脱模设备将轨道板脱出，模具钢棒附件由钢棒转移设备22收集转运。
第十三步；脱模后的轨道板模具进入清模工位1进入下一循环作业，脱模后的轨道板由运转小车托运至封锚工位23进行封锚作业。
第十四步：将封锚后的轨道板由运转小车托运至翻转设备24上大面翻转180°后对轨道板表面进行三维尺寸检测，合格品入库。
实施例一，当需要插入新规格模具时，安装预埋件涂脱模剂设备4、钢筋预紧定位设备8、张拉设备10停止接入模具进入，设备自动或手动与相应规格模具进行对应的调整与工艺预设，工艺调整位6放置有预先准备的新规格模具，并由运转小车托运至安装预埋件涂脱模剂工位4，从而实现两种模具混编进行产线进行生产。当新模具浇筑蒸养完毕即将进入放张工位时，对应放张工位的设备提前自动或手动与相应规格模具进行对应的调整与工艺预设，轨道板模具放张完毕再次混编进入生产线。与此同时，生产线的整体运行不需要停滞。
两路双工位设计的工艺设备具有功能互换的效果。
实施例二，当生产产能减小时，可关闭两路双工位工艺设备中任意一路，包括缩减蒸养房17中蒸养模块组的数量。
实施例三，当重点关键工位因故暂停工作时，生产线可继续不停机持续运行，例如：第一钢笼入位及预紧工位7的设备因故暂停工作时，轨道板模具可经由第一安装预埋件与涂脱模剂工位4、第二安装预埋件与涂脱模剂工位5、第二钢笼入位及预紧工位8、第二张拉工位10及第一张拉工位11绕行。又例如，第一张拉工位11的设备因故暂停工作时，可使该设备控制抬升，使经由第二张拉工位10流转出的运转小车可直接流转至绝缘检测设备12。
实施例四，当绝缘检测不合格且无法修复时，可经由绝缘检测不合格检修工位13进入不合格模具检修工位3将钢笼吊走，然后进入模具检测工位2再次检测并进入生产循环。
本发明采用双路双工位设计改进优化了生产中的快速应变能力，设备可备可用。同时兼容多种规格无砟轨道板模具共线运转生产轨道板，且可实现两种规格模具同时共线生产，提高了设备利用率，减少了设备投资， 自动化的设备由中控室智能化管控，采用柔性化的工艺程序可调节生产线运行的能力，更具灵活性，双工位的设计与可增减设置的蒸养模块（蒸养房），可灵活调节轨道板产量与工程进度匹配。

Claims (10)

  1. 一种先张法生产无砟轨道板的柔性流水生产线，包括按工艺顺序设置的若干个作业工位，沿所述作业工位设置的轨道及运行在所述轨道上的至少一台转运轨道板和/或轨道板模具的运转小车，所述的轨道首尾相接构成一环形轨道，其特征是设置有至少一条与所述环形轨道相接的辅助轨道，沿所述的辅助轨道上设置有作业工位。
  2. 根据权利要求1所述的先张法生产无砟轨道板的柔性流水生产线，其特征是所述的辅助轨道设置于所述环形轨道的内侧和/或外侧和/或与所述环形轨道交叉设置。
  3. 根据权利要求1、2或3所述的先张法生产无砟轨道板的柔性流水生产线，其特征是所述的轨道为有形的实体轨道或无形的供运转小车行走的地面行走路线，各生产工位按工艺顺序沿所述行走轨道/路线设置。
  4. 根据权利要求3所述的先张法生产无砟轨道板的柔性流水生产线，其特征是所述环形轨道（101）上按工艺顺序依次设置有清模工位（1），模具检测工位（2），第一安装预埋件与涂脱模剂工位（4），第一钢笼入位及预紧工位（7），第一张拉工位（11），绝缘检测工位（12），第一振动浇筑工位（14），第二振动浇筑工位（15），拉毛工位（16），蒸汽养护工位（17），放张工位（19）与脱模工位（21），设置有中控室及连接中控室的安装于各工位的作业信号检测装置。
  5. 根据权利要求4所述的先张法生产无砟轨道板的柔性流水生产线，其特征是设置有第一外侧轨道（201），所述第一外侧轨道上依次设置有第二安装预埋件与涂脱模剂工位（5），第二钢笼入位及预紧工位（8）和第二张拉工位（10），所述的第二安装预埋件与涂脱模剂工位（5），第二钢笼入位及预紧工位（8）和第二张拉工位（10）与第一安装预埋件与涂脱模剂工位（4），第一钢笼入位及预紧工位（7）和第一张拉工位（11）并行设置。
  6. 根据权利要求4或5所述的先张法生产无砟轨道板的柔性流水生产线，其特征是设置有第一内侧轨道（301）、第二内侧轨道（302）与第三内侧轨道（303），所述第一内侧轨道上设置有与模具检测工位相邻的不合格模具检修工位（3），所述第一内侧轨道上还设置有与绝缘检测工位（12）相邻的绝缘检测不合格检修区（3）,所述第二内侧轨道上设置有第二张拉工位（20），所述第三内侧轨道连接设备检修区。
  7. 根据权利要求6所述的先张法生产无砟轨道板的柔性流水生产线，其特征是设所述蒸养房与放张设备间设置有过渡工位，过渡工位与放张设备间还预留有设备维修区间。
  8. 根据权利要求6所述的先张法生产无砟轨道板的柔性流水生产线，其特征是设置有第一交叉轨道（104）与第二交叉轨道（105），所述第二交叉轨道上设置有封锚工位（23）及翻板工位（24），所述第二交叉轨道与脱模工位所在位置的轨道相接。
  9. 一种采用先张法生产无砟轨道板的柔性流水生产线运转方法，其特征是：
    第一步： 运转小车经由环形轨道（101）或辅助轨道将空模具托运至清模工位（1），将模具清理至符合工艺规范要求；
    第二步： 经清理后的模具由运转小车托运至模具检测工位(2)，由模具检测设备进行标准化检测，检测合格模具进入第一安装预埋件与涂脱模剂工位（4）或置于第二外侧轨道（202）上的第二安装预埋件与涂脱模剂工位（5）；不合格模具进入位于第一内侧轨道（301）上的不合格模具检修工位（3）待检或维修，维修后返回模具检测工位(2)再次检测；
    第三步：进入第一安装预埋件与涂脱模剂工位（4）和/或第二安装预埋件与涂脱模剂工位（5）的合格模具涂抹脱模剂并安装预埋件；
    第四步：由第一安装预埋件与涂脱模剂工位（4）上经涂抹脱模剂并安装预埋件的模具经运转小车托运至位于环形轨道上的第一钢笼入位及预紧工位（7），当第一钢笼入位及预紧工位处于检修或故障状态时该模具可经由第二外侧轨道（202）或第一交叉轨道（104）直接送入第二钢笼入位及预紧工位（8）；由第二安装预埋件与涂脱模剂工位（5）上经涂抹脱模剂并安装预埋件的模具由运转小车托运至位于第一外侧轨道（201）上的第二钢笼入位及预紧工位（8），当第二钢笼入位及预紧工位处于检修或故障状态时经第二安装预埋件与涂脱模剂工位（5）工位转出的轨道板可经由辅助轨道直接送入第一钢笼入位及预紧工位；
    第五步：进入第一钢笼入位及预紧工位（7）和/或第二钢笼入位及预紧工位（8）的轨道板模具顺序进行钢笼入位，预紧及钢棒安装；
    第六步：完成第一钢笼入位及预紧工位（7）作业的模具由运转小车托运至第一张拉工位（11）进行张拉作业，当第一张拉工位（11）处于检修或故障状态时可经由辅助轨道进入第二张拉工位（10）；完成第二钢笼入位及预紧工位（8）作业的模具由运转小车托运至第二张拉（10）进行张拉作业，当第二张拉工位处于检修或故障状态时可直接转运至第一张拉（11）；
    第七步：由第一张拉工位和/或第二张拉工位转运出的模具进入环形轨道上的绝缘检测工位（12）对钢筋进行绝缘检测，经检测合格后由运转小车托运至环形轨道上第一振动浇筑工位（14）或第二振动浇筑工位（15）；绝缘检测不合格的模具则进入绝缘检测不合格检修区（13）进行调整，然后返回绝缘检测工位（12）再次检测；
    第八步；进入振动浇筑工位的模具按设定程序进行布料、浇筑并同时进行间歇振动完成轨道板成型作业；
    第九步：成型的轨道板暨轨道板模具由运转小车托运至拉毛工位（16）由拉毛设备对轨道板模具内的轨道板裸露表面进行拉毛作业；
    第十步；完成拉毛作业的轨道板模具暨轨道板由运转小车托运至蒸养房（17）内进行蒸汽养护作业；
    第十一步： 将蒸养作业完成后的轨道板暨轨道板模具送至第一放张工位（18）或第二放张工位（19）对轨道板内的张拉钢筋进行同步放作业；
    第十二步：将完成钢筋同步放张后的轨道板暨轨道板模具运至脱模工位（21 ）由脱模设备将轨道板脱出，模具钢棒附件由钢棒转移设备（22 ）收集转运；
    第十三步；脱模后的轨道板模具进入清模工位（1）进入下一循环作业，脱模后的轨道板由运转小车托运至封锚工位（23）进行封锚作业；
    第十四步：将封锚后的轨道板由运转小车托运至翻转设备(24)上大面翻转180°后对轨道板表面进行三维尺寸检测，合格品入库。
  10. 根据权利要求9所述的采用先张法生产无砟轨道板的柔性流水生产线运转方法，其特征是：所述的第一安装预埋件与涂脱模剂工位（4）与第二安装预埋件与涂脱模剂工位（5）、第一钢笼入位及预紧工位（7）与第二钢笼入位及预紧工位（8）、第一张拉工位（11）与第二张拉工位（10）、第一放张工位（19）与第二放张工位（20）所对应的设备均设置有与不同规格模具匹配的调整位及预设工艺条件，以适应多规格型号模具的随时调整。
     
PCT/CN2018/075606 2017-07-20 2018-02-07 先张法生产无砟轨道板的柔性流水生产线 WO2019015305A1 (zh)

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