CN111015931B - Centrifugal slurry-free pile rod production process, matched material guiding mold and vibrating material distributing vehicle - Google Patents

Abstract

The invention belongs to the technical field of concrete pile rod production, and particularly relates to a centrifugal slurry-free pile rod production process, a matched material guiding mold and a vibrating material distributing vehicle; the production process of the centrifugal slurry-free pile rod comprises the following production steps: step A, preparing materials, weaving a reinforcement cage, and assembling and molding; b, preparing a dry and hard concrete material; step C, hanging the bottom die of the production die on a vibration material distribution vehicle, and cooperatively using a material guiding die to distribute materials: step D, carrying out die assembly on a cover die and a bottom die of the production die, screwing down a die assembly bolt, and tensioning the prestressed reinforcement; e, placing the production mold on a centrifuge for centrifugal operation, and then placing the production mold into a maintenance pool for maintenance; finally demoulding and taking out of the warehouse; the auxiliary device matched with the production process comprises a vibration material distribution vehicle and a material guiding mold; the invention solves the problems of product quality, environmental pollution, cost consumption, production efficiency and resource waste in the die opening material distribution process and the die closing material pumping process.

Description

Centrifugal slurry-free pile rod production process, matched material guiding mold and vibrating material distributing vehicle

Technical Field

The invention belongs to the technical field of production of concrete and cement product piles and telegraph poles, and particularly relates to a centrifugal slurry-free pile rod production process, a matched material guiding mold and a vibrating material distributing vehicle.

Background

At present, two production processes are mainly adopted in the production process of concrete piles and poles: one is a mold opening material distribution process, and the other is a mold closing material pumping process. At present, most of the production processes of centrifugal concrete pile rods are die sinking and material distributing processes. When the die sinking and distributing process is adopted for production, after concrete is distributed, the concrete generally falls on the ground or on the die edge, workers are required to shovel the material into the die, the die is closed after manual material arrangement and shape smearing are carried out after the material is distributed, the die closing bolts of the upper die and the lower die are tightened, then the process flows of prestress tensioning, centrifugal forming, residual slurry discharging, steam curing, demoulding and warehousing are carried out, the material feeding is required to be manually shoveled, the labor is more, the operation is time-consuming and labor-consuming, and the production efficiency is low. The other is a die assembly and material pumping process, which is to assemble and assemble a reinforcement cage and an end plate, die assembly is carried out on an upper die and a lower die, a concrete pump pipe is inserted into a slurry inverting hole at the tail end of the die, then concrete materials are uniformly conveyed into the die by a pump while the pump moves, then the procedures of prestress tensioning, centrifugal forming, residual slurry inversion, steam curing, demolding, warehousing and the like are carried out, and the procedures of manual material distribution, material shoveling and material shaping are omitted. The method has the defects that the pumping process has high requirement on the quality of concrete materials, the mixing proportion of the concrete needs more cement ash, the cost of the concrete is high, the water consumption of ingredients is high, the slump requirement is over 120mm, the ingredients are unstable, so the strength of the concrete is low, the stability cannot be ensured, and the use and maintenance cost of pumping process equipment is high.

Disclosure of Invention

In view of the above, the present invention is directed to a centrifugal slurry-free pile rod production process, a matched material guiding mold and a vibrating material distribution vehicle, so as to solve the problems of quality, technology, cost, waste and pollution existing in the mold opening material distribution process and the mold closing material pumping process in the prior art.

In order to achieve the purpose, the technical scheme of the invention is realized as follows:

the production process of the centrifugal slurry-free pile rod is carried out according to the following production steps in sequence:

step A, preparing materials, weaving a reinforcement cage, and assembling and molding;

b, preparing a dry and hard concrete material;

c, hanging a bottom die of the production die on a vibration distribution vehicle, hanging the material guiding die by a crane and sleeving the material guiding die on the bottom die, feeding concrete into the die from a material drainage port of the material guiding die, accumulating the concrete material in the die under the flow guiding action of the material guiding die, starting the vibration distribution vehicle after the material guiding die is fed into the die to tamp the concrete material, and stopping the vibration distribution vehicle;

d, after the concrete material is compacted, hoisting and unloading the material guiding mould by using a crane, closing the cover mould and the bottom mould of the production mould, screwing a closing bolt, and tensioning the prestressed reinforcement;

e, placing the production mold on a centrifuge for centrifugal operation, and then placing the production mold into a maintenance pool for maintenance; and finally demoulding and taking out of the warehouse.

Further, in the step B, the dry hard concrete material comprises cement, admixture, sand, gravel, water reducing agent, composite quick-change agent and water; the water-cement ratio in the components is 0.22-0.28;

wherein the composite quick-change agent is one or more of a water reducing agent, an accelerating agent, a collapse retention agent, a retarder, a lubricant and a dispersing agent;

the admixture is one or more of fly ash, slag powder, silica fume, micro-beads, lime, gypsum and an alkaline excitant;

furthermore, in the production process, when the composite quick-change agent in the concrete component adopts different components, different centrifugal process technical conditions and different tap process technical conditions are adopted.

Further, when the composite quick-change agent is a composition of a water reducing agent, a collapse-preventing agent, a retarder, a lubricant and a dispersing agent, the vibration compaction process conditions are as follows: the vibration force is at least 120 percent of the bearing capacity of the vibration device, the amplitude of the vibration is full, and the vibration time is 60-240 seconds; the centrifugal process conditions are as follows: the centrifugal force is 45-60G gravitational acceleration, and the centrifugal time is 600-1200 seconds.

Further, when the composite quick change agent is a composition of an accelerating agent, a lubricating agent and a dispersing agent, the process conditions are tapped: the vibration force is 100 percent of the bearing capacity of the vibration device, the vibration force has medium amplitude, and the vibration time is 60-180 seconds; the centrifugal process conditions are as follows: the centrifugal force is 40-55G of gravitational acceleration, and the centrifugal time is 540-960 seconds.

Further, when the composite quick change agent is a composition of a quick setting agent, a water reducing agent and a collapse-preventing agent, the process conditions of the tap compaction are as follows: the vibration force is 80 percent of the bearing capacity of the vibration device, the vibration force has medium or light amplitude, and the vibration time is 60 to 120 seconds; the centrifugal process conditions are as follows: the centrifugal force is 35-50G of gravitational acceleration, and the centrifugal time is 480-720 seconds.

Furthermore, the auxiliary device matched with the centrifugal slurry-free pile rod production process comprises a vibration material distribution vehicle and a material guiding mold, wherein the vibration material distribution vehicle comprises a bearing vehicle frame, a chassis and walking wheels, the bearing vehicle frame is elastically supported above the chassis through a plurality of groups of springs, and a plurality of groups of walking wheels are arranged on two sides of the chassis; moreover, a plurality of groups of vibrators are connected to the next line of the bearing frame in an aligned manner; the vibration material distribution vehicle runs under the traction of a winch or the driving of a motor.

The material guiding mould comprises at least one mould unit; two ends of each die unit are respectively provided with an end plate, and two adjacent die units are connected together through the end plates; wherein, the mould unit includes two drainage plates of symmetric distribution and the cross connection board that transversely links together two drainage plates.

Further, the chassis comprises a bottom plate, two sides of the bottom plate are fixedly connected with a lower side support respectively, the bearing frame comprises a top plate, two sides of the top plate are fixedly connected with an upper side support respectively, the lower side support is made of H-shaped steel, the upper side support is made of channel steel, and a spring is extruded between the lower side support and the upper side support; and a side-turning prevention structure is arranged between the lower side bracket and the upper side bracket.

Furthermore, the drainage plate is a bending plate and comprises a guiding section and a shaping section; wherein, enclose into the material drainage mouth of downward convergent form between the guide section of both sides, enclose into the accommodation space that can wrap up the steel reinforcement cage between the plastic section of both sides.

Compared with the prior art, the invention has the following advantages:

in conclusion, the purpose that no residual slurry is discharged during centrifugal forming of the pile rod is met by adopting the production process of the material guiding, compaction and centrifugal slurry-free pile rod and combining a specific concrete mixing ratio technology; and moreover, the strength of the concrete is improved, and a better concrete product is produced. Wherein, during the preparation, the dry hard concrete mixing ratio technology with low water-cement ratio is adopted, and a composite quick-change agent and a special high-performance admixture are added. After the composite quick-change agent is added, the concrete can be centrifugally compacted, the quality defect problem of the hollow honeycomb is avoided, the admixture is added, the cost can be reduced, a high-performance concrete pile with higher strength can be made, and the green product standard of material saving, energy saving, high strength and high performance is achieved.

According to the invention, when different components are adopted in the concrete, different centrifugal technical conditions and tap technical conditions are adopted in a matching way, or a specific mix proportion process technology is selected according to the difference between the centrifugal technical conditions and the tap technical conditions, so that a combined technical process system is provided, different process conditions are matched with different mix proportion technologies, and a more targeted solution is provided. The requirements of customers on product quality, price, functionality, durability and regionality can be met on the basis of meeting the product quality.

In the concrete centrifugal slurry-free pile rod production process, the production processes of shoveling, shaping and slurry pouring are eliminated, no residual slurry is formed, the process is efficient, labor-saving, material-saving, quality-guaranteeing and environment-friendly compared with a die opening material distribution process, the advantages of the die opening material distribution process and a die closing material pumping process are absorbed, the advantages of strong points and short points are achieved, the number of production workers is reduced, the production efficiency is improved, the use amount of concrete ash is reduced, and production waste generation and treatment are avoided.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate an embodiment of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:

FIG. 1 is a schematic structural diagram of a mold unit in a feeding mold according to the present invention;

FIG. 2 is a cross-sectional view at section A of FIG. 1;

FIG. 3 is a schematic view of an end panel construction;

FIG. 4 is a schematic structural view of a flow guide plate;

FIG. 5 is a schematic structural view of the support leg;

FIG. 6 is a schematic view of the assembled mold units;

FIG. 7 is a schematic view showing the use state of the dummy mold;

FIG. 8 is a schematic structural view of the vibratory material distribution cart;

FIG. 9 is a top view of FIG. 1;

FIG. 10 is a cross-sectional view at section A of FIG. 1;

fig. 11 is an enlarged schematic view of a portion B in fig. 10.

Description of reference numerals:

1-a drainage plate; 11-a guide section; 12-a shaping section; 2-end panels; 20-mounting notches; 3-a transverse connecting plate; 4-a leg; 41-a support section; 42-a connecting segment; 5-side auxiliary rib plate; 6-an upper support plate; 7-lower support plate; 8-bottom die; 9-a reinforcement cage; 011-a bottom plate; 012-lower side bracket; 021-road wheels; 022-wheel axle; 031-top plate; 032-baffle; 033-upper side bracket; 034-connecting plate; 035-blocking edge; 04-a vibrator; 051-spring; 052-positioning sleeve; 06-limiting plate; 07-tensioning the chain.

Detailed Description

It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict.

In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on those shown in the drawings, and are used only for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first", "second", etc. are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first," "second," etc. may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.

In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art through specific situations.

The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.

The production process of the centrifugal slurry-free pile rod is carried out according to the following production steps in sequence:

step A, preparing materials, weaving a reinforcement cage 9, and assembling and molding;

b, preparing a dry and hard concrete material;

step C, hanging the bottom die 8 of the production die on a vibration material distribution vehicle, and cooperatively using a material guiding die to distribute materials: hoisting the material guiding mould by a crane and sleeving the material guiding mould on the bottom mould 8, feeding concrete into the material guiding mould from a material guiding opening of the material guiding mould, accumulating the concrete material in the mould under the guiding action of the material guiding mould, starting a vibration material distributing vehicle after the material guiding mould is fed into the mould to compact the concrete material, and stopping;

d, after the concrete material is compacted, hoisting and unloading the material guiding mould by using a crane, closing the cover mould and the bottom mould 8 of the production mould, screwing a closing bolt, and tensioning the prestressed reinforcement;

e, placing the production mold on a centrifuge for centrifugal operation, and then placing the production mold into a maintenance pool for maintenance; and finally demoulding and taking out of the warehouse.

Preferably, in the step B, the dry hard concrete material comprises cement, admixture, sand, gravel, water reducer, composite quick-change agent and water; the water-cement ratio in the components is 0.22-0.28; wherein, the water-cement ratio (the mass of water in the component + the mass content of water in the composite quick-change agent): (cement mass + admixture mass);

wherein the composite quick-change agent is one or more of a water reducing agent, an accelerating agent, a collapse retention agent, a retarder, a lubricant and a dispersing agent;

the admixture is one or more of fly ash, slag powder, silica fume, micro-beads, lime, gypsum and an alkaline excitant;

the invention provides a new production process, which is named as a material-guiding and vibrating centrifugal slurry-free production process, and preferably, in the production process, when different components are adopted as composite quick-change agents in concrete components, different centrifugal process technologies and different vibrating process technologies are adopted in a matching mode. In the production process, which mix proportion and which process condition are adopted, the mold closing requirement is met, and the centrifugal redistribution of the concrete material cannot be influenced by over-vibration. Different concrete mix proportion, the required vibratory force and tap time are different, different centrifugal conditions need to be adopted in a targeted manner under different process schemes and different mix proportion conditions, otherwise the requirement of a mold closing process cannot be met.

The first, (1) embodiment is as follows:

example 1:

the composite quick-change agent is a composition of a water reducing agent, a collapse-preventing agent, a retarder, a lubricant and a dispersing agent,

the concrete comprises the following components: 280Kg of cement, 120Kg of admixture (wherein, the mass percentages of all the substances are 20 percent of slag powder, 55 percent of fly ash, 12 percent of micro-beads, 8 percent of silica fume and 5 percent of excitant), 690Kg of sand, 1380Kg of broken stone, 9.5Kg of water reducer, 3Kg of composite quick-change agent (wherein, the mass percentages of all the substances are 30 percent of water reducer, 30 percent of collapse-protecting agent, 30 percent of retarder, 5 percent of lubricant and 5 percent of dispersant) and 80Kg of water;

the production process comprises the following steps: a material guiding, compacting, centrifuging and pulp-free production process;

specifically, the tapping process conditions are as follows: the vibration force is at least 150 percent of the bearing force (comprising a mould, a pile in the mould and a mould bearing platform), the full amplitude is realized, and the vibration time is 160 seconds; the centrifugal process conditions are as follows: the centrifugal force is 55G gravity acceleration, and the centrifugal time is 720 seconds;

the experiment shows that: the strength of the concrete is 95 MPa; the pulp yield is 0 kg/square;

the product quality is as follows: the concrete is compact, has no hollow honeycomb and has excellent quality.

Example 2:

the composite quick change agent is a composition of a quick setting agent, a lubricant and a dispersant,

the concrete comprises the following components: 280Kg of cement, 130Kg of admixture (wherein, the mass percentages of all the substances are 30 percent of slag powder, 45 percent of fly ash, 8 percent of micro-beads, 12 percent of silica fume and 5 percent of excitant), 670Kg of sand, 1380Kg of broken stone, 8.5Kg of water reducer, 4Kg of composite quick-change agent (wherein, the mass percentages of all the substances are 60 percent of quick-change agent, 20 percent of lubricant and 20 percent of dispersant) and 90Kg of water.

The production process comprises the following steps: a material guiding, compacting, centrifuging and pulp-free production process;

specifically, the tapping process conditions are as follows: the vibration force is 100 percent of the bearing force (comprising a mould, an in-mould pile and a mould bearing platform), the vibration amplitude is moderate, and the vibration time is 160 seconds; the centrifugal process conditions are as follows: the centrifugal force is 45G gravitational acceleration, and the centrifugal time is 720 seconds;

the experiment shows that: the strength of the concrete is 92 MPa; the pulp yield is 0 kg/square;

the product quality is as follows: the concrete is compact, has no hollow honeycomb and has excellent quality.

Example 3:

the composite quick-change agent is a composition of a quick-setting admixture, a water reducing agent and a collapse-preventing agent,

the concrete comprises the following components: 290Kg of cement, 130Kg of admixture (wherein, the mass percentages of all the substances are 40 percent of slag powder, 20 percent of fly ash, 5 percent of micro-beads, 16 percent of silica fume, 5 percent of quicklime, 5 percent of gypsum and 7 percent of excitant), 670Kg of sand, 1380Kg of broken stone, 8.2Kg of water reducer, 4.8Kg of quick-change agent (wherein, the mass percentages of all the substances are 40 percent of quick-change agent, 40 percent of polyether carboxylic acid water reducer and 20 percent of foaming agent) and 90Kg of water;

the production process comprises the following steps: a material guiding, compacting, centrifuging and pulp-free production process;

specifically, the tapping process conditions are as follows: the vibration force is 70 percent of the bearing force (comprising a mould, an in-mould pile and a mould bearing platform), the vibration force has medium or light amplitude, and the vibration time is 120 seconds; the centrifugal process conditions are as follows: the centrifugal force was 37G acceleration of gravity and the centrifugal time was 600 seconds.

The experiment shows that: the strength of the concrete is 90 MPa; the pulp yield is 0 kg/square;

the product quality is as follows: the concrete is compact, has no hollow honeycomb and has excellent quality.

(2) The comparative examples are as follows:

comparative example 1:

the concrete comprises the following components: 315Kg of cement, 135Kg of slag powder, 670Kg of sand, 1300Kg of crushed stone, 10Kg of water reducing agent and 128Kg of water;

the production process comprises the following steps: a mold opening and material distribution production process (in the prior art);

the experiment shows that: the strength of the concrete is 85 MPa; the pulp output is 90 Kg/square (the residual pulp contains 36Kg of water and 54Kg of powder);

the product quality is as follows: the concrete density is poor, and the number of hollow honeycombs is large.

Comparative example 2:

the concrete comprises the following components: 350Kg of cement, 150Kg of slag powder, 680Kg of sand, 1210Kg of broken stone, 12Kg of water reducing agent and 155Kg of water;

the actual water-cement ratio of the concrete is 0.265 when the measured discharge amount of each side is about 118 Kg, the rest slurry contains 52Kg of water and the powder material contains 66Kg of powder material

The production process comprises the following steps: a mold closing and material pumping production process (the prior art);

the experiment shows that: the strength of the concrete is 83 MPa; the pulp output is 118 Kg/square (the residual pulp contains 52Kg of water and 66Kg of powder);

the product quality is as follows: the density of the concrete is poor, and a few hollow honeycombs exist.

Secondly, data comparison and analysis:

(1) the comparison of the data of the above embodiment and the comparative example shows that the purpose of discharging no residual slurry by centrifugation can be met by adopting the dummy material compaction centrifugal slurry-free production process and combining a specific concrete formula; under the action of a specific centrifugal force, the water in the concrete is just equal to the water consumption for cement hydration, and the aim of discharging residual slurry without centrifugation is fulfilled. Compared with the traditional mold opening material distribution production process (the general slurry output is 85-95 kg/square) and the mold closing pump material production process (the general slurry output is 110-.

In the invention, because the centrifugal discharge of no residual slurry can be realized, 40 kg/square of cement ash can be saved, the ash loss and waste caused by the discharge of the residual slurry are avoided, and because the low water-ash ratio dry-hard concrete mixing ratio technology is adopted, the concrete slump is small, the water consumption for mixing is small, and the quality is ensured to be stable. The use amount of ash materials with the same concrete mixing proportion can be reduced by centrifuging without discharging excess slurry. And no residual slurry is discharged after centrifugal molding, so that the problem of pollution of residual slurry tailings and waste materials in the conventional material distribution process is solved, the environmental pollution treatment cost of the residual slurry and the waste materials is reduced, and the comprehensive production and manufacturing cost is saved.

(2) By comparing the data of the embodiment and the comparative example, the strength of the concrete can be improved by adopting the feed-guiding compaction centrifugal slurry-free production process and combining a specific concrete formula; the concrete strengths of examples 1-3 were all above 90MPa, while the concrete strengths of comparative examples were all below 85 MPa.

In the invention, the water-cement ratio in the dry hard concrete material is 0.22-0.28; the method is different from the prior mold opening material distribution process (the water cement ratio of concrete is generally 0.3-0.36) and the mold closing material pumping process (the water cement ratio of concrete is generally 0.4-0.5);

in the production process, the water-cement ratio is controlled to be 0.22-0.28, and is the mixing ratio of low water-cement ratio; because the technology of low water cement ratio dry and hard concrete mixing ratio is adopted, the concrete slump is small, the range is small and controllable, the water consumption of concrete mixing materials is small, slurry is not discharged after centrifugal molding, no water slurry flows to wash an interface of aggregate, the interface bonding force is large, and the strength of a concrete structure is high.

In addition, because the formula of the invention contains the special high-performance admixture which is an admixture suitable for the production process, the admixture which is doped by 20-50 percent can improve the strength and durability of concrete, improve the microstructure of the concrete, reduce micro-gaps and achieve the purposes of saving materials and meeting the standard of high-strength high-performance green products. In addition, the admixture replaces part of the cement consumption, thereby reducing industrial pollution and saving cost.

Therefore, the mixing ratio technology with low water-cement ratio is combined with the addition of high-performance admixture, so that the structural strength of the concrete is comprehensively improved.

(3) By comparing the data of the above examples and comparative examples, the invention can obtain the product concrete compact, no-cavity honeycomb and excellent quality by adopting the dummy material compaction centrifugal non-slurry production process and combining with a specific concrete formula.

In order to realize that no residual slurry is discharged after centrifugation, the water cement ratio in the concrete formula is reduced, so that the concrete material slump is not more than 20mm, the water consumption of concrete ingredients is low, and no slurry is discharged after centrifugal molding; however, the water-cement ratio is simply reduced, so that no residual slurry can be discharged, but when the concrete with the low water-cement ratio is simply used, the quality defect that the concrete is not compact due to centrifugation and the product is easy to produce a hollow honeycomb can be caused because the concrete material is dry; therefore, in the formula, 0.1-1% of composite quick change agent (aqueous agent/powder agent) is added to adjust the process state of the concrete material, so that the dry and hard concrete has soft performance, the concrete is well distributed and filled into a mold, the production operability requirement is met, the soft performance of the concrete can be quickly recovered during centrifugal rolling after the concrete is subjected to material guiding, shape guiding, compaction and mold closing, the concrete can be centrifugally compacted, the quality defect problem of hollow honeycombs is avoided, and the problem that the dry and hard concrete is easy to have poor centrifugal compaction is solved.

Therefore, due to the addition of the composite quick-change agent, the product quality can be considered on the premise of no residual slurry discharge during centrifugation, and the problems of poor centrifugal compactness and easiness in occurrence of quality defects of hollow honeycombs in a low water-cement ratio formula are solved.

(4) In conclusion, the purpose of discharging no residual slurry in centrifugation can be met by adopting the material-guiding, vibrating, compacting and centrifuging slurry-free production process and combining a specific concrete formula; in addition, the strength of the concrete is improved, and the product quality is also considered. According to the invention, when different components are adopted for coagulation, different centrifugal process conditions and different tap process conditions are adopted in a matching manner, or a specific formula is selected according to different centrifugal process conditions and different tap process conditions, so that a combined technical process system is provided, different process conditions are matched and used at different mixing ratios, and the method is more targeted. The requirements of customers on product quality, price, functionality, durability and regionality can be met on the basis of meeting the product quality.

Meanwhile, the auxiliary device matched with the production process of the centrifugal slurry-free pile rod comprises a vibration material distribution vehicle and a material guiding mold, and is specifically introduced as follows:

as shown in fig. 1 to 7, a dummy mold includes at least one mold unit; two ends of each die unit are respectively provided with an end plate 2, and two adjacent die units are connected together through the end plates 2;

the mould unit comprises two symmetrically distributed drainage plates 1 and a transverse connecting plate 3 for transversely connecting the two drainage plates 1 together; in the embodiment, the thickness of the drainage plate 1 is 3-15mm, the width of the drainage plate is 300-1200 mm, the thickness of the transverse connecting plate 3 is 3-15mm, and the distance is 0.5-4 m.

The drainage plate 1 is a bending plate and comprises a guide section 11 and a shaping section 12; wherein, enclose into the material drainage mouth of downward convergent form between the guide section 11 of both sides, enclose into the accommodation space that can wrap up steel reinforcement cage 9 between the plastic section 12 of both sides.

Preferably, the shaping segment 12 is an inwardly concave arc plate or a plane sloping plate, and the shape and the size of the shaping segment are determined according to the pile shape to be produced so as to be suitable for different pile type specifications. The included angle alpha between the slope plate of the guide section 11 and the horizontal plane is 30-70 degrees.

Preferably, in the mold unit, a plurality of support legs 4 are fixedly connected to the side wall of each drainage plate 1, and the support legs 4 are symmetrically distributed on two sides of the mold unit. The leg 4 includes a support section 41 and a connection section 42 which are integrally formed; wherein the connecting section 42 is welded on the side wall of the drainage plate 1, the supporting section 41 inclines outwards, and the supporting section 41 is gradually reduced from top to bottom. Set up stabilizer blade 4, can steadily support this material mould of drawing through stabilizer blade 4 on the one hand subaerial, on the other hand, because support section 41 inclines to the outside, and support section 41 is the convergent form from top to bottom, makes both sides stabilizer blade 4 be the flaring form like this, when placing this material mould of drawing on die block 8, plays certain guide effect for this mould can be put just more easily.

Preferably, the lower extreme of end panel 2 is equipped with curved installation notch 20, because this mould is placed on steel reinforcement cage 9, installation notch 20 is used for giving steel reinforcement cage 9 the position of stepping down, is convenient for place. End panel 2 welds simultaneously at the end of two drainage plates 1, and is equipped with a plurality of connecting holes on end panel 2, and end panel 2 between two adjacent mould units pastes tightly and is in the same place through bolted connection.

In the invention, the material guiding mould is formed by sequentially and detachably splicing a plurality of mould units; the lengths of the die units are different, and the material guiding die with the required length can be formed by combining and splicing different lengths so as to produce pile rods with different lengths.

Preferably, a plurality of side auxiliary rib plates 5 are welded on the outer side of the drainage plate 1 and used for enhancing the supporting strength and the connecting strength of the material guiding mold. The thickness of the side auxiliary rib plate 5 is 3-15mm, and the distance is 0.5-4 m.

Preferably, the upper end of the drainage plate 1 is provided with an upper support plate 6, the upper end of the drainage plate 1 is provided with a lower support plate 7, and the side auxiliary rib plate 5 is welded with the upper support plate 6, the lower support plate 7 and the drainage plate 1 at the same time.

As shown in fig. 8-11, a vibration material distribution vehicle comprises a load-bearing frame, a chassis and a plurality of traveling wheels 021, wherein the load-bearing frame is elastically supported above the chassis through a plurality of groups of springs 051, and a plurality of groups of traveling wheels 021 are arranged at two sides of the chassis; moreover, a plurality of groups of vibrators 04 are connected to the next line of the bearing frame in an aligned mode; the vibration material distribution vehicle drives the flat car to travel on the rail by traction of a winch or motor drive; the reel is additionally arranged at the head and the tail of the chassis and is matched with a winch for use.

The chassis comprises a bottom plate 011, two sides of the bottom plate 011 are fixedly connected with a lower side support 012 respectively, the load-bearing frame comprises a top plate 031, two sides of the top plate 031 are fixedly connected with an upper side support 033 respectively, the lower side support 012 adopts H-shaped steel, the upper side support 033 adopts channel steel, and a spring 051 is extruded between the lower side support 012 and the upper side support 033; the channel-section steel of roof 031 both sides links together through a connecting plate 034, and vibrator 04 demountable installation is in connecting plate 034 lower surface.

The springs 051 adopt high-strength springs 051, 13 groups or 15 groups are arranged, and the diameter of the springs 051, the height of the springs 051 and the outer diameter are respectively not smaller than 10mm, 150mm and 80 mm; the stroke compression amount of the spring 051 after the pressure bearing support is supported by 200KN is not more than 60 percent.

The length of the bearing frame is designed to be 10-15 meters, the height of the top plate 031 and the track surface is 370mm according to the length specification design of a workshop, the height is limited and not limited, and the width of the surface of the top plate 031 is 1200 mm. The vibrator 04 can adopt a vibrating motor or a pneumatic vibrator 04, the total vibration force is not less than 200KN, 14 vibrators 04 are uniformly arranged to provide vibration sources, the vibration sources are 2-level strength vibration sources, and the materials of a bearing frame and a chassis of the flat car have enough steel toughness.

The bottom plate 011 is down to dismantle the rigid coupling through the bolt and be equipped with many shaft 022, and walking wheel 021 passes through the bearing rotatable installation at shaft 022 terminally, and walking wheel 021 adopts the rail wheel. The travelling wheel 021 adopts 6 groups of high-strength through-shaft inner bearing wheels, the position space is balanced properly, the overhaul, the maintenance and the replacement of the vibrator 04 are not influenced, the shaft diameter is not less than 80mm, the wheel diameter is about 200mm, and the adopted roller bearing wheel is required to have shock resistance.

Preferably, a web plate of the H-shaped steel is fixedly connected with a positioning sleeve 052 with an upward opening, and the bottom surface of the channel steel is fixedly connected with a positioning sleeve 052 with a downward opening; the spring 051 is compressed between two locating sleeves 052.

Preferably, a rollover prevention structure is further provided between the lower side bracket 012 and the upper side bracket 033. The side turning prevention structure comprises a limiting plate 06 and a tensioning chain 07, the lower end of the limiting plate 06 is fixedly connected to the outer side of the H-shaped steel, the upper end of the limiting plate 06 is tightly attached to the outer side of the channel steel in parallel, the lower end of the tensioning chain 07 is fixedly connected to the outer side of the limiting plate 06, and the upper end of the tensioning chain 07 is fixedly connected to the lower surface of a top plate 031.

Install limiting plate 06 additional through both sides and can retrain the upset of upper portion collateral branch frame 033 slope, and then play the upper strata and bear the frame and prevent the effect of turning on one's side, install taut chain 07 additional simultaneously, taut chain 07 is in the tensioning state, and it is taut with the upper strata and bear the frame, can reduce the lateral pressure to limiting plate 06 when can reduce the upper strata and bear the frame and pile up inhomogeneous the turning on one's side because of the material, prevent that limiting plate 06 from damaging, play the overload protection effect.

Preferably, roof 031 upper surface rigid coupling has two parallel arrangement's baffle 032, and baffle 032 adopts the angle steel, and the angle steel back-off welds in roof 031 upper surface. Be used for erectting the production mould between two baffles 032, prevent that the production mould from rolling.

Preferably, two side edges of the top plate 031 are further respectively and fixedly connected with a retaining edge 035.

Preferably, the front end of the chassis is provided with a contact switch. The contact switch fixed point is installed at the head end of the chassis and is a starting switch of the vibrator 04, during installation, safety and work are not influenced, and the flat car is contacted and electrified when moving to a preset position.

Preferably, the front end and the tail end of the flat car are provided with a light-sensitive radar and an acousto-optic warning lamp, and when the flat car runs, the flat car can safely give an alarm and automatically stop.

In the centrifugal slurry-free pile rod production process, after a bottom die 8 of a production die is hung on a vibration material distribution vehicle, a material guide die is hung and sleeved on the bottom die 8 by a crane, at the moment, a reinforcement cage 9 is just sleeved between shaping sections 12 of two drainage plates 1, required concrete is fed from a material drainage port enclosed between guide sections 11 of the drainage plates 1, the concrete material is accumulated in the die under the flow guide effect of the drainage plates 1, the material distribution is completed, then, a flat car is driven to travel to a set position on a track by a winch, a contact switch arranged at the head end of a chassis is contacted and electrified, a vibrator 04 of the vibration material distribution vehicle is started to vibrate and compact the loose concrete material in the die and stop the loose concrete material after the bulk is reduced to meet the process operation requirements of die assembly, and the original manual operation procedures of material shoveling and shape smearing are replaced.

In the material guiding mould, due to the shaping effect of the shaping section 12 of the drainage plate 1, when the material guiding mould is lifted, concrete is uniformly attached to the reinforcement cage 9, and concrete materials cannot collapse to the outside of the side mould. The material guiding mold is mainly used for the material distribution process of concrete piles for guiding materials and shaping, the effect of equipment guiding is standard and smooth, and the material guiding mold is used for replacing the effect of manual material shoveling and shaping, so that the material (concrete) of the cloth cannot fall outside the mold and needs manual material shoveling and shaping, and the process link of the original manual material shoveling and shaping is reduced and avoided. The problem of traditional cloth fill need artifical shovel material, complicated operation such as plastic at the cloth in-process and traditional cloth fill be not suitable for hard concrete cloth is solved.

Because the concrete belongs to the type of hard concrete, the flow is small, the void ratio of the material is large, the material is more, the material cannot be distributed in the mould and must be piled up, and because the concrete material is loose, the volume is large, the pile height is higher, the upper mould cover cannot be arranged, the mould cannot be closed, and the subsequent operations such as centrifugation and the like cannot be carried out, the upper layer of the vibration distribution vehicle has the vibration function, and the vibration compaction of the concrete which is loose and distributed in the material guiding mould and the bottom mould 8 can be reduced to the position capable of covering the mould so as to carry out the subsequent operations.

Therefore, the centrifugal slurry-free pile rod production process is a novel centrifugal concrete pile production process, production processes of shoveling, shaping and slurry pouring are omitted, the process is efficient, labor-saving, material-saving, quality-guaranteeing and environment-friendly compared with a die opening and material distributing process, the advantages of the die opening and material distributing process and a die closing and material pumping process are absorbed and improved, advantages and disadvantages are brought to the greatest extent, the number of workers can be reduced, production efficiency can be improved, ash of concrete can be reduced, and production waste and treatment of production waste can be reduced.

The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.

Claims (6)

1. The production process of the centrifugal slurry-free pile rod is characterized by comprising the following steps: the method comprises the following steps:

step A, preparing materials, weaving a reinforcement cage (9) and assembling and forming;

b, preparing a dry and hard concrete material;

step C, hanging a bottom die (8) of the production die on a vibration material distribution vehicle, and cooperatively using a material guiding die to distribute materials: hoisting the material guiding mould by a crane and sleeving the material guiding mould on the bottom mould (8), feeding concrete into the material guiding opening of the material guiding mould, accumulating the concrete material in the mould under the guiding action of the material guiding mould, starting the vibration material distribution vehicle after the material guiding mould is fed into the mould to tap the concrete material, and stopping the operation;

d, after the concrete material is compacted, hoisting and unloading the material guiding mould by using a crane, closing the cover mould and the bottom mould (8) of the production mould, screwing a closing bolt, and tensioning the prestressed reinforcement;

e, placing the production mold on a centrifuge for centrifugal molding, and then placing the mold into a maintenance pool for maintenance; finally, demoulding and delivering the product out of the warehouse;

in the production process, when the composite quick-change agent in the concrete components adopts different components, different centrifugal process conditions and different tap process conditions are adopted;

when the composite quick-change agent is a composition of a water reducing agent, a collapse-maintaining agent, a retarder, a lubricant and a dispersing agent, the compaction process conditions are as follows: the vibration force is at least 120 percent of the bearing capacity of the vibration device, the amplitude of the vibration is full, and the vibration time is 60-240 seconds; the centrifugal process conditions are as follows: the centrifugal force is 45-60G gravitational acceleration, and the centrifugal time is 600-1200 seconds;

when the composite quick change agent is a composition of a quick setting agent, a lubricating agent and a dispersing agent, the vibration process conditions are as follows: the vibration force is 100 percent of the bearing capacity of the vibration device, the vibration force has medium amplitude, and the vibration time is 60-180 seconds; the centrifugal process conditions are as follows: the centrifugal force is 40-55G of gravitational acceleration, and the centrifugal time is 540-960 seconds;

when the composite quick-change agent is a composition of an accelerating agent, a water reducing agent and a collapse-preventing agent, the vibration process conditions are as follows: the vibration force is 80 percent of the bearing capacity of the vibration device, the vibration force has medium or light amplitude, and the vibration time is 60 to 120 seconds; the centrifugal process conditions are as follows: the centrifugal force is 35-50G of gravitational acceleration, and the centrifugal time is 480-720 seconds.

2. The centrifugal slurry-free pile rod production process according to claim 1, wherein: in the step B, the dry and hard concrete material comprises cement, admixture, sand, gravel, water reducing agent, composite quick-change agent and water; the water-cement ratio in the components is 0.22-0.28;

wherein the composite quick-change agent is one or more of a water reducing agent, an accelerating agent, a collapse retention agent, a retarder, a lubricant and a dispersing agent;

the admixture is one or more of fly ash, slag powder, silica fume, micro-beads, lime, gypsum and an alkaline activator.

3. The centrifugal slurry-free pile rod production process according to claim 1, wherein: the material guiding mould comprises at least one mould unit; two ends of each die unit are respectively provided with an end plate (2), and two adjacent die units are connected together through the end plates (2); the mould unit comprises two symmetrically distributed drainage plates (1) and a transverse connecting plate (3) which transversely connects the two drainage plates (1) together.

4. The centrifugal slurry-free pile rod production process according to claim 3, wherein: the drainage plate (1) is a bent plate and comprises a guide section (11) and a shaping section (12); wherein, enclose into the material drainage mouth of convergent form downwards between the guide section (11) of both sides, enclose into the accommodation space that can wrap up steel reinforcement cage (9) between the plastic section (12) of both sides.

5. A vibrating cloth cart for use in the manufacturing process according to any one of claims 1 to 4, characterized in that:

the vibrating material distribution vehicle comprises a bearing frame, a chassis and travelling wheels (021), wherein the bearing frame is elastically supported above the chassis through a plurality of groups of springs (051), and a plurality of groups of travelling wheels (021) are arranged at two sides of the chassis; moreover, a plurality of groups of vibrators (04) are connected to the next line of the bearing frame in an aligned manner; the vibration material distribution vehicle runs under the traction of a winch or the driving of a motor.

6. The vibratory feeding cart of claim 5, wherein: the chassis comprises a bottom plate (011), two sides of the bottom plate (011) are respectively fixedly connected with a lower side support (012), the bearing frame comprises a top plate (031), two sides of the top plate (031) are respectively fixedly connected with an upper side support (033), the lower side support (012) adopts H-shaped steel, the upper side support (033) adopts channel steel, and a spring (051) is extruded between the lower side support (012) and the upper side support (033); and a side-turning prevention structure is arranged between the lower side bracket (012) and the upper side bracket (033).

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