WO2018036186A1 - Automatic pre-tensioned prestress concrete slab manufacturing technique utilized in assembly line - Google Patents
Automatic pre-tensioned prestress concrete slab manufacturing technique utilized in assembly line Download PDFInfo
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- WO2018036186A1 WO2018036186A1 PCT/CN2017/082110 CN2017082110W WO2018036186A1 WO 2018036186 A1 WO2018036186 A1 WO 2018036186A1 CN 2017082110 W CN2017082110 W CN 2017082110W WO 2018036186 A1 WO2018036186 A1 WO 2018036186A1
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 61
- 238000000034 method Methods 0.000 title claims abstract description 46
- 239000004567 concrete Substances 0.000 title claims abstract description 25
- 230000007246 mechanism Effects 0.000 claims abstract description 10
- 230000005540 biological transmission Effects 0.000 claims abstract description 5
- 229910000831 Steel Inorganic materials 0.000 claims description 61
- 239000010959 steel Substances 0.000 claims description 61
- 238000006243 chemical reaction Methods 0.000 claims description 44
- 238000004140 cleaning Methods 0.000 claims description 32
- 230000008569 process Effects 0.000 claims description 28
- 238000005516 engineering process Methods 0.000 claims description 27
- 238000007689 inspection Methods 0.000 claims description 25
- 239000011513 prestressed concrete Substances 0.000 claims description 25
- 238000005507 spraying Methods 0.000 claims description 19
- 230000009471 action Effects 0.000 claims description 15
- 238000007605 air drying Methods 0.000 claims description 14
- 239000003795 chemical substances by application Substances 0.000 claims description 14
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- 230000036541 health Effects 0.000 claims description 10
- 238000004873 anchoring Methods 0.000 claims description 9
- 238000012423 maintenance Methods 0.000 claims description 9
- 239000007921 spray Substances 0.000 claims description 7
- 238000001816 cooling Methods 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
- 238000009434 installation Methods 0.000 claims description 5
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- 229910001294 Reinforcing steel Inorganic materials 0.000 claims 1
- 230000002787 reinforcement Effects 0.000 claims 1
- 238000013461 design Methods 0.000 description 6
- 230000003014 reinforcing effect Effects 0.000 description 5
- 239000011150 reinforced concrete Substances 0.000 description 4
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Classifications
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- 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
- 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
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/04—Producing shaped prefabricated articles from the material by tamping or ramming
- B28B1/045—Producing shaped prefabricated articles from the material by tamping or ramming combined with vibrating or jolting
-
- 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
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- 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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
- B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
- B28B13/023—Feeding the moulding material in measured quantities from a container or silo by using a feed box transferring the moulding material from a hopper to the moulding cavities
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- 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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/04—Discharging the shaped articles
- B28B13/06—Removing the shaped articles from moulds
- B28B13/065—Removing the shaped articles from moulds by applying electric current or other means of discharging, e.g. pneumatic or hydraulic discharging means
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- 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
-
- 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
- B28B17/0063—Control arrangements
- B28B17/0081—Process control
-
- 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
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- 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
- B28B7/382—Devices for treating, e.g. sanding
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
- E01B1/00—Ballastway; Other means for supporting the sleepers or the track; Drainage of the ballastway
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01B—PERMANENT WAY; PERMANENT-WAY TOOLS; MACHINES FOR MAKING RAILWAYS OF ALL KINDS
- E01B1/00—Ballastway; Other means for supporting the sleepers or the track; Drainage of the ballastway
- E01B1/002—Ballastless track, e.g. concrete slab trackway, or with asphalt layers
Definitions
- the invention provides a pre-tensioned prestressed concrete track plate assembly line automatic manufacturing technology, and has the following characteristics: that is, when the model flow is transferred to the prestressed steel tensioning station, the model is subjected to the prestressing Tensile stress of the steel bar.
- the above-mentioned reinforcing bar cage is provided with a steel bar die-injecting device component
- the finished board inspection station is provided with a finished board inspection equipment component
- Step 3 The model enters the process of model cleaning and release agent spraying and air drying station, and the process of cleaning and spraying the release agent on the model;
- Step 17 The model enters the model ferry station 2, and the model with the product enters the release station through the ferry device.
- the pre-tensioned prestressed concrete track plate assembly line automatic manufacturing system includes an automated assembly line track and several models;
- Step 8 The model enters station 11 or 12 and tensions the prestressed steel bars with tensioning equipment.
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- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Automation & Control Theory (AREA)
- Bridges Or Land Bridges (AREA)
- Manufacturing Of Tubular Articles Or Embedded Moulded Articles (AREA)
Abstract
An automatic pre-tensioned prestress concrete slab manufacturing technique utilized in an assembly line comprising at least one assembly line track and at least one template. A plurality of stations are arranged on the assembly line track, and templates are moved, by a template moving mechanism, and at a pace, from stations to stations on the assembly line track. Sensors are arranged at all the stations, and transmit, to a central control system, signals of completion states and completion quality of corresponding tasks at the stations. The central control system controls, according to the signals, the pace of operating the entire system. The manufacturing process achieves automatic control and transmission of key data information, and increases production efficiency.
Description
本发明涉及高速铁路轨道结构中轨道板产品的一种制造方法。一种先张法双向预应力钢筋混凝土轨道板机组流水线自动化制造技术，特别涉及传统先张法制造技术向自动化，信息化制造技术的转换。The present invention relates to a method of manufacturing a track plate product in a high speed railway track structure. A prefabricated two-way prestressed reinforced concrete track plate assembly line automatic manufacturing technology, especially relates to the conversion of traditional pretensioning manufacturing technology to automation and information manufacturing technology.
目前，公知的高速铁路轨道板有先张法结构和后张法结构两种方式，因此，有两种制造方式，这两种制造方式的共同特点是固定台位法模式。At present, the known high-speed railway track plates have two methods: a pre-tensioning structure and a post-tensioning structure. Therefore, there are two manufacturing methods, and the common feature of the two manufacturing methods is the fixed-position method.
所谓固定台位法模式是指模型不动，其它作业工序配合模型轮番作业的方式。比如，传统先张法制造工艺首先是设计建造一个持力结构物，将预应力钢筋一端锁定在结构物上，另一端进行张拉至设计值时将张拉力锁定在模型以外结构物上，然后进行其它工序的作业。The so-called fixed-position method refers to the way in which the model does not move, and other work processes are matched with the model rotation. For example, the traditional pretensioning process is first of all to design and build a holding structure, one end of the prestressed reinforcing bar is locked on the structure, and the other end is stretched to the design value to lock the tensile force on the structure outside the model, and then Perform other operations.
在混凝土强度大于设计强度的75％时将张拉的预应力钢筋松开，预应力钢筋产生弹性回缩，对混凝土构件形成压缩内应力。典型的先张法生产方式有CRTSⅡ高速铁路轨道板，民用空心楼板，大型预制桥梁，这些构件都是单向先张法设计，并且制造原理都采用固定台位法模式，预应力钢筋为通长结构，构件与构件之间通过切割的方式将预应力钢筋断开。When the concrete strength is greater than 75% of the design strength, the tensioned prestressed steel bars are loosened, and the prestressed steel bars are elastically retracted to form a compressive internal stress on the concrete members. Typical pre-tensioning production methods include CRTSII high-speed railway track panels, civil hollow floor slabs, and large prefabricated bridges. These components are designed in one-way pretensioning, and the manufacturing principle is based on the fixed table method. The prestressed steel bars are long. The structure, the member and the member are cut by means of cutting to break the prestressed steel bar.
2012年，铁道科学研究院设计了一种先张法双向预应力混凝土轨道板，预应力钢筋不是传统方式的通长钢筋，而是根据轨道板纵横向长度专门设计的尺寸，两端开有螺纹，并在螺纹的尽头拧上锚固板，生产后预应力钢筋不露出轨道板表面，对此，在传统先张法生产技术的基础上开发了一种固定模型的矩阵法生产方式，所谓矩阵法是指先设计建造一个矩形的钢筋混凝土张拉坑，承受
预应力钢筋的张拉应力，8套模型放置张拉坑内，预应力钢筋通过连接杆在不同模型之间连接，组成通长。然后进行张拉，之后的工艺方式同固定台位模式相同。固定台位模式制造工艺的特点是人机配合，自动化程度低，用工数量较多，劳动强度较大，生产周期为20h-22h，效率较低，张拉坑占用生产场地较大，而且，产品生产完毕后其张拉坑无法搬迁，形成浪费；产品质量受到工艺条件限制，波动性较大，监管靠抽查，漏洞多。In 2012, the Institute of Railway Science designed a pretensioned two-way prestressed concrete track slab. The prestressed steel is not a traditional long-length steel bar, but is specially designed according to the longitudinal and lateral length of the track plate. And the anchor plate is screwed at the end of the thread. After the production, the prestressed steel bar does not expose the surface of the track plate. Based on the traditional pretensioning production technology, a fixed model matrix method is developed. The so-called matrix method It refers to the design and construction of a rectangular reinforced concrete tensioning pit, which bears
Tensile stress of prestressed steel bars, 8 sets of models are placed in the tension pits, and prestressed steel bars are connected between different models through connecting rods to form a length. Then the tension is applied, and the subsequent process is the same as the fixed station mode. The fixed-stage mode manufacturing process is characterized by man-machine cooperation, low degree of automation, large number of labor, high labor intensity, production cycle of 20h-22h, low efficiency, and large production space for Zhanglao pit, and, After the completion of production, the Zhang pull pit can not be relocated, resulting in waste; the product quality is limited by the process conditions, the volatility is large, the supervision relies on spot checks, and there are many loopholes.
发明内容Summary of the invention
本发明旨在克服上述缺陷，提供一种可实现全自动化管理和制造的、无需固定张拉抬等临时建筑、高效率的先张法预应力混凝土轨道板机组流水线自动化制造技术。The invention aims to overcome the above drawbacks, and provides an automated manufacturing technology of a pre-tensioned prestressed concrete track plate assembly line which can realize full automation management and manufacture without temporary tensioning and other temporary construction and high efficiency.
本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：包含至少一条流水线轨道和至少一个模型；在实际制造的过程中，为了提高制造的效率，可根据实际需要进行多个模型，或多条并行或交错轨道的设置。The invention provides a pre-tensioned prestressed concrete track plate assembly line automatic manufacturing technology, which comprises: at least one pipeline track and at least one model; in the actual manufacturing process, in order to improve the manufacturing efficiency, according to the actual situation Multiple models are required, or multiple parallel or staggered track settings.
该模型即为制造轨道板的模具，该模型可以根据目标轨道板的不同规格和造型，进行不同模型的预设和调整。The model is a mold for manufacturing a track plate, and the model can be preset and adjusted according to different specifications and shapes of the target track plate.
上述流水线轨道上设有若干工位；该工位是指根据轨道板制造工艺的需要，进行不同功能的操作工位的设置。The above-mentioned pipeline track is provided with a plurality of stations; the station refers to the setting of operation stations for performing different functions according to the needs of the manufacturing process of the track plate.
上述模型在模型流转机构的作用下，按照时间节拍，在流水线轨道上的各工位间进行流转；The above model is flowed between stations in the pipeline track according to the time tempo under the action of the model flow mechanism;
基于用于制造轨道板的模型的固有特点，在本发明中模型流转机构一般为用于大型设备移动的牵引机构。
Based on the inherent characteristics of the model used to manufacture the track panels, in the present invention the model flow mechanism is typically a traction mechanism for the movement of large equipment.
其中，上述时间节拍为每个工位的工作时间。该时间节拍可以为每个工位单独预设的或受中央控制***统一调配的方式进行。Among them, the above time beat is the working time of each station. This time tempo can be preset for each station individually or by a central control system.
进一步地，本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，还具有这样的特点：即、上述工位上均设有传感器；Further, the invention provides a pre-tensioned prestressed concrete track plate assembly line automatic manufacturing technology, and has the following features: that is, the above stations are provided with sensors;
上述传感器将各工位上相应工作的完成状态和完成质量的信号传输到中央控制***；The above sensor transmits a signal of completion status and quality of completion of the corresponding work at each station to the central control system;
上述中央控制***根据上述信号，控制整个***运转的时间节拍。该中央控制***一般将每个工位或指定的多个工位的完成信号进行统计后，下达所有工位或指定工位上的模具流转到下一个程序的指令。The central control system controls the time tempo of the entire system operation based on the above signals. The central control system generally counts the completion signals of each station or a plurality of designated stations, and then issues the instructions of the mold flow to all the stations or the designated stations to the next program.
进一步地，本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，还具有这样的特点：即、上述模型流转机构包括牵引***、行程开关、信号转换控制器、控制***组成；Further, the invention provides a pre-tensioned prestressed concrete track plate assembly line automatic manufacturing technology, and has the following features: that is, the model flow conversion mechanism comprises a traction system, a stroke switch, a signal conversion controller, and a control system. ;
上述牵引***、行程开关、信号转换控制器、控制***之间电气连接。该模型流转机构根据中央控制***的流转指令，通过采用如：牵引机等设备实现模型在流水线轨道上的流动，该移动的具***移及是否到达指定工位的位置受行程开关的控制。The above traction system, the travel switch, the signal conversion controller, and the control system are electrically connected. According to the flow instruction of the central control system, the model flow mechanism realizes the flow of the model on the pipeline track by using equipment such as a tractor, and the specific displacement of the movement and the position of reaching the designated station are controlled by the travel switch.
进一步地，本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，还具有这样的特点：即、上述工位包括沿模型流动的方向依次设置的放张工位、脱模工位、模型清理和脱模剂喷洒及风干工位、预埋件安装工位、钢筋笼入模工位、预应力钢筋连接工位、绝缘检测工位、预应力钢筋张拉工位、模型变形检测工位、混凝土布料及振捣工位、模型表面清理工位、模型摆渡工位一、喷雾养生工位、升温工位、恒温工位、降温工位、模型摆渡工位二；每个工位上都有相应的工作设备或支持设备，完成该工位上的规定动作，
动作参数达到流水线设定的要求，其质量标准达到先张法预应力混凝土轨道板技术条件要求。Further, the present invention provides a pre-tensioned prestressed concrete track plate assembly line automatic manufacturing technology, which also has the following features: that is, the above-mentioned work station includes a positioning station arranged in the direction of the flow of the model, and the demoulding Work station, model cleaning and release agent spraying and air drying station, embedded parts installation station, steel cage mold station, prestressed steel connection station, insulation inspection station, prestressed steel tension station, model Deformation inspection station, concrete fabric and vibrating station, model surface cleaning station, model ferry station 1, spray health station, heating station, constant temperature station, cooling station, model ferry station 2; There are corresponding working equipment or supporting equipment at the station to complete the prescribed actions on the station.
The action parameters meet the requirements of the pipeline setting, and the quality standard meets the technical requirements of the pretensioned prestressed concrete track plate.
其中，各上述工位在流水线轨道上的设置数量为一个或一个以上；Wherein, the number of the above stations is set on the pipeline track is one or more;
上述流水线轨道呈环形结构；The above pipeline track has a ring structure;
上述各工位沿模型流动的方向依次设置在流水线轨道上。Each of the above stations is sequentially disposed on the pipeline track in the direction in which the model flows.
进一步地，本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，还具有这样的特点：即、当模型流转到预应力钢筋张拉工位后，由模型来承受预应力钢筋的张拉应力。Further, the invention provides a pre-tensioned prestressed concrete track plate assembly line automatic manufacturing technology, and has the following characteristics: that is, when the model flow is transferred to the prestressed steel tensioning station, the model is subjected to the prestressing Tensile stress of the steel bar.
进一步地，本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，还具有这样的特点：即、当模型流转到放张工位后，通过电动扭转的方式来卸出张拉应力。Further, the automatic manufacturing technology of the pre-tensioned prestressed concrete track plate unit assembly line provided by the invention also has the following features: that is, after the model flow is transferred to the release station, the sheet is unloaded by electric torsion. Pulling stress.
进一步地，本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，还具有这样的特点：即、上述中央控制***由包括传感器、信号转换控制器、软件、DCS模块的设备组成；用于监控、收集和分析各工位的工作状态，并对各工位下达工作指令。Further, the invention provides a pre-tensioned prestressed concrete track plate assembly line automatic manufacturing technology, and has the following features: that is, the central control system comprises a device including a sensor, a signal conversion controller, a software, and a DCS module. Composition; used to monitor, collect and analyze the working status of each station, and issue work orders for each station.
上述放张工位上设有放张设备组件；The above-mentioned release station is provided with a release device assembly;
上述放张设备组件包括棘轮咬合头，传动齿轮组，伺服电机，位移计，滑动槽，千斤顶，信号转换控制器；用于通过电动扭转的方式，采用组合齿轮带动多根预应力钢筋的连接杆同时反转动的方法，卸出张拉应力，并将完成状态的信号发送至中央控制***；上述各组件之间通过电气连接。The above-mentioned tensioning device assembly comprises a ratchet biting head, a transmission gear set, a servo motor, a displacement meter, a sliding groove, a jack, a signal conversion controller, and a connecting rod for driving a plurality of prestressed reinforcing bars by a combined gear by means of electric torsion At the same time, the method of reverse rotation unloads the tensile stress and sends a signal of the completion state to the central control system; the above components are electrically connected.
上述脱模工位上设有脱模设备组件；The demolding device assembly is provided on the demolding station;
上述脱模设备组件包括千斤顶、位移计、信号转换控制器；用于将制造完成的轨道板从模型上脱离出来，并将完成状态的信号发送至中央控制***；上
述各组件之间通过电气连接。The demolding device assembly includes a jack, a displacement meter, and a signal conversion controller; the utility model is configured to detach the manufactured rail plate from the model, and send a signal of the completion state to the central control system;
Electrical connections are made between the components.
上述模型清理和脱模剂喷洒及风干工位上设有模型清理设备组件、脱模剂喷涂设备组件和风干设备组件；The model cleaning and release agent spraying and air drying station are provided with a model cleaning device component, a release agent spraying device component and an air drying device component;
上述模型清理设备组件包括电动刷，滑动槽，吸尘器，行程开关，信号转换控制器；用于对脱模后的空模型进行残留清理的工作，并将完成状态的信号发送至中央控制***；上述各组件之间通过电气连接。The model cleaning device assembly includes an electric brush, a sliding slot, a vacuum cleaner, a travel switch, a signal conversion controller, a residual cleaning operation for the demoped empty model, and a signal of the completion state is sent to the central control system; The components are electrically connected.
上述脱模剂喷涂设备组件包括喷雾器、滑动槽、行程开关，信号转换控制器；用于对完成清理工作的模型进行脱模剂喷涂的工作，并将完成状态的信号发送至中央控制***；上述各组件之间通过电气连接。The above-mentioned release agent spraying equipment assembly comprises a sprayer, a sliding groove, a stroke switch, a signal conversion controller; a work for releasing the mold release agent for the model for completing the cleaning work, and transmitting the signal of the completion state to the central control system; The components are electrically connected.
上述风干设备组件包括热风机，喷嘴，滑动槽，行程开关，信号转换控制器；用于对完成脱模剂喷涂的模型进行最后的风干步序，从而为下个轨道板的制造做准备工作，并将完成状态的信号发送至中央控制***；上述各组件之间通过电气连接。The air drying equipment component comprises a hot air blower, a nozzle, a sliding slot, a travel switch, a signal conversion controller, and a final air drying step for the model for completing the release agent spraying, thereby preparing for the manufacture of the next track board. The signal of the completion status is sent to the central control system; the above components are electrically connected.
上述钢筋笼入模工位上设有钢筋入模设备组件；The above-mentioned reinforcing bar cage is provided with a steel bar die-injecting device component;
上述钢筋入模设备组件包括行车、吊装工具；用于将钢筋骨架通过吊装的方法放置到模型内，并将完成状态的信号发送至中央控制***，上述各组件之间通过电气连接。The above-mentioned steel bar-injection equipment assembly includes a driving and lifting tool; the steel frame is placed into the model by lifting, and the signal of the completion state is sent to the central control system, and the above components are electrically connected.
上述预应力钢筋连接工位上设有连接设备组件；The pre-stressed steel bar connection station is provided with a connection device component;
上述连接设备组件包括夹具，气动扭力扳手，信号转换控制器；上述各组件之间通过电气连接。The above connecting device assembly includes a clamp, a pneumatic torque wrench, and a signal conversion controller; the above components are electrically connected.
上述预应力钢筋张拉工位上设有张拉设备组件；The prestressed steel tensioning station is provided with a tensioning device assembly;
上述张拉设备组件包括定位顶升/下降千斤顶、U型力爪、千斤顶、测力传感器、位移传感器、油泵、控制***和楔形块、气动缸、信号转换控制器；用
于对每根预应力钢筋完成张拉工作，该张拉方式为多个千斤顶组成的张拉方式，其中，每个千斤顶控制一根预应力钢筋，并通过应力传感器和计算机组成的***来控制千斤顶的工作步骤，而模型与千斤顶互为反力，单向张拉，至设计值后进行锁定，至此张拉***设备完成工作，并将完成状态的信号发送至中央控制***，上述各组件之间通过电气连接。The tensioning device assembly includes a positioning jacking/lowering jack, a U-shaped force claw, a jack, a load cell, a displacement sensor, an oil pump, a control system and a wedge block, a pneumatic cylinder, and a signal conversion controller;
The tensioning work is completed for each prestressed steel bar, and the tensioning method is a tensioning method composed of a plurality of jacks, wherein each jack controls a prestressed steel bar, and the jack is controlled by a system consisting of a stress sensor and a computer. The working steps, and the model and the jack are mutually reactive, one-way tensioning, locking to the design value, until the tensioning system equipment completes the work, and sends the completion status signal to the central control system, between the above components Through electrical connections.
上述混凝土布料及振捣工位上设有振捣设备组件、布料设备组件和送料设备组件；The above-mentioned concrete cloth and vibrating station is provided with a vibrating device component, a cloth device component and a feeding device component;
上述振捣设备组件包括两分块刚性支架、振动电机、控制器组成振捣设备；用于实现混凝土振捣的工序，上述各组件之间通过电气连接。The vibrating device assembly comprises a two-part rigid support, a vibration motor and a controller to form a vibrating device; a process for realizing concrete vibrating, wherein the above components are electrically connected.
上述布料设备组件包括料斗、底部液压开合门、附着式振捣电机、滑动槽、行程开关、信号转换控制器，上述各组件之间通过电气连接。The above-mentioned cloth equipment assembly includes a hopper, a bottom hydraulic opening and closing door, an attached vibrating motor, a sliding groove, a stroke switch, and a signal conversion controller, and the above components are electrically connected.
上述送料设备组件包括混凝土搅拌站、料斗、导轨、电动平车、信号转换控制器，用于向模型内输送混凝土，并将完成状态的信号发送至中央控制***，上述各组件之间通过电气连接。The above feeding device assembly comprises a concrete mixing station, a hopper, a guide rail, an electric flat car, a signal conversion controller for conveying concrete into the model, and transmitting a signal of the completion state to the central control system, and the above components are electrically connected .
上述喷雾养生工位包括养护设备组件；The above spray health station includes a maintenance equipment component;
上述养护设备组件包括养护罩、喷雾器、温度计、湿度计、锅炉、分压器、分隔门或风幕、信号转换控制器；用于对完成浇筑的模型进行养护的工序，并将完成状态的信号发送至中央控制***，上述各组件之间通过电气连接。The above-mentioned maintenance equipment components include a maintenance cover, a sprayer, a thermometer, a hygrometer, a boiler, a voltage divider, a partition door or a wind curtain, a signal conversion controller, a process for curing a mold to be completed, and a signal of completion status Sended to the central control system, the above components are electrically connected.
上述绝缘检测工位和模型变形检测工位上设有检测设备组件；并将完成状态的信号发送至中央控制***，上述各组件之间通过电气连接。The above-mentioned insulation detecting station and the model deformation detecting station are provided with detecting device components; and the signal of the completion state is sent to the central control system, and the above components are electrically connected.
上述检测设备组件包括激光扫描器、滑动槽、行程开关、三维照拍***、信息检测转换***、单板机及相应软件，实现各阶段的检测需要，上述各组件之间通过电气连接
The above detection device components include a laser scanner, a sliding slot, a travel switch, a three-dimensional photographing system, an information detection conversion system, a single board machine and corresponding software, and the detection needs of each stage are realized, and the above components are electrically connected.
进一步地，本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，还具有这样的特点：即、上述流水线轨道上还设有身份识别工位，用于识别该模型内的轨道板的型号、规格等参数；Further, the present invention provides a prefabricated prestressed concrete track plate assembly line automatic manufacturing technology, which also has the feature that an identification station is also provided on the pipeline track for identifying the model. The model and specifications of the track board;
还包括依次设置的成品翻转工位、成品封锚工位、成品板检测工位；It also includes a finished product reversing station, a finished sealing station, and a finished board inspection station.
当轨道板完成脱模后，上述轨道板依次在成品翻转工位、成品封锚工位、成品板检测工位间进行流转。After the track plate is demolded, the track plate is sequentially flowed between the finished product turning station, the finished sealing station, and the finished board detecting station.
进一步地，本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，还具有这样的特点：即、上述成品翻转工位上设有成品翻转设备组件；Further, the invention provides a pre-tensioned prestressed concrete track plate assembly line automatic manufacturing technology, and has the following features: that is, the finished product turning station has a finished product turning device assembly;
上述成品翻转设备组件包括行车、吊装工具；用于通过吊装设备等工序来实现产品的翻转工作，上述各组件之间通过电气连接。The above-mentioned finished product reversing device component comprises a driving and lifting tool; and the product is turned over by a process such as lifting equipment, and the above components are electrically connected.
上述成品封锚工位上设有封锚设备组件；The above-mentioned finished sealing and anchoring station is provided with an anchoring device assembly;
上述封锚设备组件由搅拌机、填压机；用于实现对各连接杆卸载后的预应力钢筋的端部进行封锚的工作，上述各组件之间通过电气连接。The above-mentioned anchoring device assembly is composed of a mixer and a filling machine; and is used for sealing the ends of the prestressed reinforcing bars after the unloading of the connecting rods, and the above components are electrically connected.
上述成品板检测工位上设有成品板检测设备组件；The finished board inspection station is provided with a finished board inspection equipment component;
上述成品板检测设备组件包括激光扫描器、滑动槽、行程开关、三维照拍***、信息检测转换***、单板机及相应软件，上述各组件之间通过电气连接，实现产品的各技术指标的检测。The above-mentioned finished board detecting equipment component comprises a laser scanner, a sliding slot, a travel switch, a three-dimensional photographing system, an information detecting conversion system, a single board machine and corresponding software, and the above various components are electrically connected to realize various technical indexes of the product. Detection.
进一步地，本发明提供的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，还具有这样的特点：即、由如下工艺步骤来实现：Further, the present invention provides a pre-tensioned prestressed concrete track plate assembly line automatic manufacturing technology, which also has the following features: that is, by the following process steps:
步骤一：不同型号模型通过模型流转机构流动到放张工位，对产品进行放张作业；Step 1: Different model models flow through the model transfer mechanism to the release station to perform the release operation of the product;
步骤二：模型进入脱模工位，将产品从模型中顶出；
Step 2: The model enters the demolding station and the product is ejected from the model;
步骤三：模型进入模型清理和脱模剂喷洒及风干工位，对模型进行清理、喷涂隔离剂的工序；Step 3: The model enters the process of model cleaning and release agent spraying and air drying station, and the process of cleaning and spraying the release agent on the model;
步骤四：模型进入预埋件安装工位，将产品预埋件进行安装；Step 4: The model enters the embedded parts installation station to install the embedded parts of the product;
步骤五：模型进入钢筋笼入模工位，将钢筋笼入模；Step 5: The model enters the steel cage into the mold station, and the steel cage is inserted into the mold;
步骤六：模型进入预应力钢筋连接工位，用连接杆对预应力钢筋进行连接；Step 6: The model enters the prestressed steel connection station, and the prestressed steel bars are connected by the connecting rod;
步骤七：模型进入绝缘检测工位，对钢筋笼的绝缘状况进行检测；Step 7: The model enters the insulation inspection station to detect the insulation condition of the steel cage;
步骤八：模型进入预应力钢筋张拉工位，用张拉设备对预应力钢筋进行张拉；Step 8: The model enters the prestressed steel tensioning station, and the tensioning steel bar is tensioned by the tensioning device;
步骤九：模型进入模型变形检测工位，用激光三维扫描仪对模型尺寸进行检测；Step 9: The model enters the model deformation detection station, and the model size is detected by a laser three-dimensional scanner;
步骤十：模型进入混凝土布料及振捣工位，灌注混凝土并振捣；Step 10: The model enters the concrete fabric and vibrating station, injects concrete and vibrates;
步骤十一：模型进入模型表面清理工位，进行模型的表面清洗；Step 11: The model enters the surface cleaning station of the model to perform surface cleaning of the model;
步骤十二：模型进入模型摆渡工位一，通过摆渡设备将模型送入到养生区；Step 12: The model enters the model ferry station, and the model is sent to the health area through the ferry equipment;
步骤十三：模型进入喷雾养生工位，通过喷水雾的方式控制温度和湿度养生；Step 13: The model enters the spray health station to control temperature and humidity by spraying water mist;
步骤十四：模型进入升温工位，按照技术条件要求进行升温；Step 14: The model enters the heating station and heats up according to the technical requirements;
步骤十五：模型进入恒温工位，按照技术条件要求进行恒温；Step 15: The model enters a constant temperature station and is thermostated according to technical requirements;
步骤十六：模型进入降温工位，按照技术条件要求进行降温；Step 16: The model enters the cooling station and is cooled according to the technical requirements;
步骤十七：模型进入模型摆渡工位二，通过摆渡设备让带有产品的模型进入放张工位。Step 17: The model enters the model ferry station 2, and the model with the product enters the release station through the ferry device.
本发明的作用和效果：The effects and effects of the present invention:
本发明所涉及先张法双向预应力钢筋混凝土轨道板自动化机组流水线制造
技术，其显著特点是模型流动，模型承担张拉应力，各工位在流水线上一字排开，在同一时间共同作业，可以实现每7-10分钟生产一块轨道板的目的。与矩阵生产方法相比，取消了张拉台座等临时建筑，模型周转率提高50％，厂房面积减少了30％以上，用工数量减少50％以上。生产过程实现全自动控制，关键数据信息化传输，远程监控，所有设备可以跟随工程需要搬迁和快速安装的目的。The invention relates to a prefabricated two-way prestressed reinforced concrete track plate automatic unit assembly line manufacturing
The remarkable feature of the technology is that the model flows, the model bears the tensile stress, and each station is lined up on the assembly line. Working together at the same time, the purpose of producing a track plate every 7-10 minutes can be achieved. Compared with the matrix production method, the temporary building such as the tension pedestal is eliminated, the model turnover rate is increased by 50%, the plant area is reduced by more than 30%, and the number of labor is reduced by more than 50%. The production process realizes automatic control, key data information transmission, remote monitoring, and all equipment can follow the project needs to be relocated and quickly installed.
由此可见，本发明提供的先张法双向预应力钢筋混凝土轨道板自动化机组流水线制造技术，创造了新的功效价值和质量价值以及信息价值，形成一个全新产业链。It can be seen that the prefabricated two-way prestressed reinforced concrete track plate automatic assembly line manufacturing technology provided by the invention creates new efficacy value, quality value and information value, and forms a brand new industrial chain.
附图1、本实施例涉及的先张法预应力混凝土轨道板机组流水线自动化制造***的示意图；FIG. 1 is a schematic view showing an automated manufacturing system of a pretensioned prestressed concrete track plate unit assembly line according to the embodiment; FIG.
其中，1、2-放张工位；3、4--脱模工位；5-模型清理工位；6-安装预埋件及检测工位；7-钢筋笼入模工位；8、9-预应力钢筋连接工位；10-绝缘检测工位；11、12-同步张拉工位；13-模型检测工位；14-混凝土浇筑振捣工位；15-模型清理工位；16-牵引摆渡一工位；17-养生区工位；18-升温区工位；19-恒温区工位；20-降温区工位；21-牵引摆渡二工位。Among them, 1, 2 - release station; 3, 4-- demoulding station; 5 - model cleaning station; 6 - installation of embedded parts and inspection stations; 7 - steel cage into the mold station; 9-Prestressed steel connection station; 10-Insulation inspection station; 11, 12-synchronous tensioning station; 13-model inspection station; 14-concrete pouring vibrating station; 15-model cleaning station; - Traction ferry one station; 17-health area station; 18-heating zone station; 19-constant temperature zone station; 20-cooling zone station; 21-towing ferry two stations.
如图1所示，本实施例提供的先张法预应力混凝土轨道板机组流水线自动化制造***，包含自动化流水线轨道和若干模型；As shown in FIG. 1 , the pre-tensioned prestressed concrete track plate assembly line automatic manufacturing system provided by the embodiment includes an automated assembly line track and several models;
该自动化流水线轨道呈矩形设置，包括轨道板制造主工序用轨道110、摆渡去程轨道120、水养区轨道130、摆渡回程轨道140。
The automated pipeline track is arranged in a rectangular shape, and includes a track plate manufacturing main process track 110, a ferry going track 120, a water maintenance zone track 130, and a ferry return track 140.
在轨道板制造主工序用轨道110上，设有若干工位，按轨道板制造的顺序依次为放张工位1和2；脱模工位3和4；模型清理工位5；安装预埋件及检测工位6；钢筋笼入模工位7；预应力钢筋连接工位8和9；绝缘检测工位10；同步张拉工位11和12；模型检测工位13；混凝土浇筑振捣工位14；模型清理工位15。On the track 110 for the main process of the track plate manufacturing, a plurality of stations are provided, in the order of the manufacture of the track plates, the laying stations 1 and 2; the demolding stations 3 and 4; the model cleaning station 5; Parts and inspection station 6; steel cage into the mold station 7; prestressed steel connection station 8 and 9; insulation inspection station 10; synchronous tensioning stations 11 and 12; model inspection station 13; concrete pouring vibration Station 14; model cleaning station 15.
其中，放张工位1和2上固定有放张设备组件，由括棘轮咬合头、传动齿轮组、伺服电机、位移计、滑动槽、千斤顶、信号转换控制器组成；该放张方式为电动扭转方式，当载有成品的模型流转到该工位时，通过组合齿轮带动多根预应力钢筋的连接杆同时反转动，卸出张拉应力。该工位上还设有传感器等感应设备，当完成上述动作后，将完成信号和质量回传中央控制***，等待下一步的指令。Wherein, the tensioning device 1 and 2 are fixed with a releasing device component, which is composed of a ratchet biting head, a transmission gear set, a servo motor, a displacement meter, a sliding slot, a jack, and a signal conversion controller; the releasing method is electric In the torsion mode, when the model flow carrying the finished product is transferred to the station, the connecting rods of the plurality of prestressed steel bars are driven by the combined gears to rotate at the same time, and the tensile stress is discharged. The station also has sensing devices such as sensors. When the above actions are completed, the signal and quality are returned to the central control system, waiting for the next command.
该脱模工位3和4上设有脱模设备组件，由千斤顶、位移计、信号转换控制器组成；当模型卸除张拉应力后到达该工位，通过千斤顶等设备将成品顶出模型进行脱模的工序。该工位上还设有传感器等感应设备，当完成上述动作后，将完成信号和质量回传中央控制***，等待下一步的指令。The demoulding stations 3 and 4 are provided with a demoulding device assembly, which is composed of a jack, a displacement meter and a signal conversion controller; when the model unloads the tensile stress, the model is reached, and the finished product is pushed out of the model by a jack or the like. The process of demolding is performed. The station also has sensing devices such as sensors. When the above actions are completed, the signal and quality are returned to the central control system, waiting for the next command.
另外，完成脱模的成品，进入成品后处理区域200。该后处理区域200中也设有与轨道板制造主工序用轨道110相关联的自动化流水线轨道，该轨道上依次设有成品翻转工位、成品封锚工位、成品板检测工位。当轨道板成品脱模后，通过自动化的摆渡设备流转到后处理区域200后，依次在上述三个工位上进行相关的工艺处置后，将获得的混凝土轨道板移至产品仓待用。In addition, the finished product of the demolding is completed and enters the finished post-treatment area 200. The post-processing area 200 is also provided with an automated pipeline track associated with the track-making main process track 110, which is provided with a finished product reversing station, a finished sealing station, and a finished board inspection station. After the finished product of the track plate is demolded, after being transferred to the after-treatment area 200 through the automated ferry device, the relevant process is disposed on the above three stations in turn, and the obtained concrete track plate is moved to the product warehouse for use.
其中，在成品翻转工位上设有成品翻转设备组件，由行车、吊装工具等设备组成，当成品板完成脱模流转到该工位时，可通过吊装车等工具将成品板翻转，该工位上还设有传感器等感应设备，当完成上述动作后，将完成信号和质
量回传中央控制***，等待下一步的指令。Wherein, the finished product turning equipment component is arranged on the finished product turning station, and is composed of driving, lifting tools and the like. When the finished product board completes the demoulding flow and is transferred to the working position, the finished product board can be turned over by a lifting vehicle or the like. There are also sensors and other sensing devices on the bit. When the above actions are completed, the signal and quality will be completed.
The quantity is passed back to the central control system and waiting for the next step.
在成品封锚工位上设有封锚设备组件，由封锚设备组件由搅拌机、填压机等设备组成，当成品板完成翻转后被流转至该工位时，可通过填压机等设备将搅拌完成的混凝土等填料填充至预应力钢筋的端部实现封锚的效果；在该工位上还设有传感器等感应设备，当完成上述动作后，将完成信号和质量回传中央控制***，等待下一步的指令。An anchoring device component is arranged on the finished sealing and anchoring station, and the sealing and anchoring device component is composed of a mixer, a filling machine and the like. When the finished plate is turned over and then transferred to the station, the device can be passed through a filling machine or the like. Filling the finished concrete and other fillers to the end of the prestressed steel bar to achieve the effect of sealing the anchor; at the station, there are also sensors and other sensing devices, and when the above actions are completed, the signal and quality return central control system will be completed. Wait for the next step.
在成品板检测工位上设有成品板检测设备组件，由激光扫描器、滑动槽、行程开关、三维照拍***、信息检测转换***、单板机及相应软件组成，当完成上述所有工序后，通过最后的检测工序来实现对成品板是否符合质量标准和工艺标准的检验，当检验合成后可送至仓库待用。The finished board inspection equipment component is provided on the finished board inspection station, and is composed of a laser scanner, a sliding slot, a travel switch, a three-dimensional photographing system, an information detection conversion system, a single board machine and corresponding software, after all the above processes are completed. Through the final inspection process to achieve the inspection of whether the finished board meets the quality standards and process standards, when the inspection is synthesized, it can be sent to the warehouse for use.
此外，如图1所示，模型清理工位5上设有模型清理设备组件、脱模剂喷涂设备组件和风干设备组件；In addition, as shown in FIG. 1 , the model cleaning station 5 is provided with a model cleaning device component, a release agent spraying device component and an air drying device component;
该模型清理设备组件由电动刷，滑动槽，吸尘器，行程开关，信号转换控制器等设备组成；该脱模剂喷涂设备组件由喷雾器、滑动槽、行程开关，信号转换控制器等设备组成；该风干设备组件由热风机，喷嘴，滑动槽，行程开关，信号转换控制器等设备组成；当模型卸除产品后，在模型清理工位5上完成模型的清理、脱模剂的喷涂和风干的工序，以待制作下一班轨道板用。在该工位上还设有传感器等感应设备，当完成上述动作后，将完成信号和质量回传中央控制***，等待下一步的指令。The model cleaning device component is composed of an electric brush, a sliding slot, a vacuum cleaner, a travel switch, a signal conversion controller and the like; the mold release agent spraying device component is composed of a sprayer, a sliding slot, a travel switch, a signal conversion controller and the like; The air drying equipment component is composed of a hot air blower, a nozzle, a sliding slot, a travel switch, a signal conversion controller, etc.; after the model is unloaded, the model cleaning, the release agent spraying and the air drying are completed at the model cleaning station 5. The process is to be used for the next track plate. At the station, there are also sensing devices such as sensors. When the above actions are completed, the signal and quality are returned to the central control system, waiting for the next command.
之后的安装预埋件及检测工位6上将产品预埋件首先进行安装，当完成上述动作后，将完成信号和质量回传中央控制***，等待下一步的指令。After the installation of the embedded parts and the inspection station 6, the product embedded parts are first installed. When the above actions are completed, the signal and quality are returned to the central control system, waiting for the next instruction.
之后的钢筋笼入模工位7上设有钢筋入模设备组件，由行车、吊装工具等设备组成，通过吊装车等工具将钢筋笼置入模型中，该工位上还设有传感器等
感应设备，当完成上述动作后，将完成信号和质量回传中央控制***，等待下一步的指令。After that, the steel cage is placed in the mold station 7 and is provided with a steel bar-injection equipment component, which is composed of driving and lifting tools, and the steel cage is placed into the model by a tool such as a lifting truck, and a sensor is also provided at the station.
The sensing device, when the above actions are completed, will complete the signal and quality return to the central control system and wait for the next command.
之后的预应力钢筋连接工位8和9上设有连接设备组件，由夹具、气动扭力扳手、信号转换控制器等设备组成，当完成钢筋入模后，通过气动扭转的方式，实现连接杆对每一根预应力钢筋的连接，该工位上，对应于每根预应力钢筋的位置均设有传感器等感应设备，当完成上述动作后，将完成信号和质量回传中央控制***，等待下一步的指令。After the prestressed steel bar connection stations 8 and 9 are provided with connecting equipment components, which are composed of fixtures, pneumatic torque wrenches, signal conversion controllers, etc., after the completion of the steel bar into the mold, the connecting rod pair is realized by pneumatic torsion. The connection of each prestressed steel bar, the position corresponding to each prestressed steel bar is equipped with sensors and other sensing devices. When the above actions are completed, the signal and quality return to the central control system will be completed, waiting for the next One step instruction.
之后的绝缘检测工位10上设有检测设备，通过使用仪器对钢筋笼的绝缘状况进行检测后，将完成信号和质量回传中央控制***，等待下一步的指令。After the insulation inspection station 10 is equipped with testing equipment, after using the instrument to detect the insulation condition of the steel cage, the signal and quality are returned to the central control system, waiting for the next instruction.
之后的同步张拉工位11和12上设有张拉设备组件，由定位顶升/下降千斤顶、U型力爪、千斤顶、测力传感器、位移传感器、油泵、控制***和楔形块、气动缸、信号转换控制器；在本实施例中，该张拉方式为多个千斤顶组成的张拉方式，其中，每个千斤顶控制一根预应力钢筋，并有一个应力传感器和计算机组成的***来控制千斤顶的工作步骤。模型与千斤顶互为反力，单向张拉，至设计值后进行锁定，张拉***完成工作，当完成上述动作后，将整体完成信号和质量回传中央控制***，等待下一步的指令。The subsequent synchronous tensioning stations 11 and 12 are provided with tensioning device components, such as positioning jacking/lowering jacks, U-shaped claws, jacks, load cells, displacement sensors, oil pumps, control systems and wedge blocks, pneumatic cylinders. The signal conversion controller; in the embodiment, the tensioning method is a tensioning method composed of a plurality of jacks, wherein each jack controls a prestressed reinforcing bar, and has a system composed of a stress sensor and a computer to control The working steps of the jack. The model and the jack are mutually reactive, one-way tensioning, locking to the design value, the tensioning system completes the work, and when the above actions are completed, the overall completion signal and quality are returned to the central control system, waiting for the next instruction.
之后的模型检测工位13上设有检测设备，通过采用激光三维扫描仪对模型尺寸进行检测，当符合标准时，将完成信号和质量回传中央控制***，等待下一步的指令。The model inspection station 13 is then provided with a detection device for detecting the size of the model by using a laser three-dimensional scanner. When the standard is met, the signal and quality are returned to the central control system, waiting for the next instruction.
之后的混凝土浇筑振捣工位14上设有振捣、布料和送料设备组件300；该振捣设备组件包括两分块刚性支架、振动电机、控制器组成振捣设备；该布料设备组件包括料斗、底部液压开合门、附着式振捣电机、滑动槽、行程开关、信号转换控制器；该送料设备组件包括混凝土搅拌站、料斗、导轨、电动平车、
信号转换控制器；通过上述设备来灌注混凝土并进行振捣的工序，当完成上述动作后，将完成信号和质量回传中央控制***，等待下一步的指令。The subsequent concrete pouring vibrating station 14 is provided with a vibrating, fabric and feeding device assembly 300; the vibrating device assembly comprises a two-part rigid support, a vibration motor, and a controller to form a vibrating device; the cloth device assembly includes a hopper , bottom hydraulic opening and closing door, attached vibrating motor, sliding slot, travel switch, signal conversion controller; the feeding equipment components include concrete mixing station, hopper, guide rail, electric flat car,
Signal conversion controller; through the above equipment to inject concrete and vibrate the process, when the above actions are completed, the signal and quality are returned to the central control system, waiting for the next instruction.
之后的模型清理工位15上设有清理设备，对完成混凝土灌注的模型进行表面的清洗工作，该工位上设有传感器等感应设备，当完成上述动作后，将完成信号和质量回传中央控制***，等待下一步的指令。The model cleaning station 15 is provided with cleaning equipment to clean the surface of the concrete-filled model. The station is equipped with sensors and other sensing devices. When the above actions are completed, the signal and quality are returned to the center. Control the system and wait for the next step.
当完成了上述初步的制造工序后，模型将被流转到摆渡去程轨道120，通过设于该轨道120上的牵引摆渡工位16来实现，将模型转移至水养区域400的目的。Upon completion of the preliminary manufacturing process described above, the model will be transferred to the ferry outbound track 120 for the purpose of transferring the model to the watering zone 400 via the towed station 16 disposed on the track 120.
在水养区域400中，根据现场面积和实际制造效率的要求，可设有有若干条水养区轨道130，在本实施例中，设有130a、130b、130c、130d、130e五组组合轨道，来完成轨道板的水养流程。In the water-reinforcing area 400, according to the requirements of the site area and the actual manufacturing efficiency, a plurality of water-care zone rails 130 may be provided. In this embodiment, five sets of combined rails 130a, 130b, 130c, 130d, and 130e are provided. To complete the water maintenance process of the track board.
其中，每条轨道上均按功能的、依次设有多个养生区工位17、升温区工位18、恒温区工位19和降温区工位20。上述多个工位均为有由温度计、水池等设备组成的水养设备，每个工位上均设有计时器、传感器等设备，当完成某一阶段的工序后，将完成信号和质量回传中央控制***，等待下一步的指令。Among them, each track is provided with a plurality of health zone stations 17, a heating zone station 18, a constant temperature zone station 19 and a cooling zone station 20 according to functions. The above-mentioned multiple stations are all water-care equipment consisting of thermometers, pools, etc. Each station is equipped with timers, sensors and other equipment. When a certain stage of the process is completed, the signal and quality will be completed. Pass the central control system and wait for the next step.
当完成了上述养护工序后，模型将被流转到摆渡回程轨道140上，通过设于该轨道140上的牵引摆渡工位21来实现，将模型从水养区域400转移回轨道板制造主工序用轨道110上的目的。After the above maintenance process is completed, the model will be transferred to the swing return track 140, and realized by the traction and shifting station 21 provided on the track 140, and the model will be transferred from the water culture zone 400 back to the main process of the track plate manufacturing. The purpose on track 110.
在本实施例中，模型在各工位之间的流转通过模型流转牵引设备来完成，该设备由牵引***、行程开关、信号转换控制器、控制***等设备组成。In this embodiment, the flow of the model between the stations is completed by the model flow traction device, which is composed of a traction system, a travel switch, a signal conversion controller, a control system, and the like.
在本实施例中，中央控制***由包括传感器、信号转换控制器、软件、DCS模块的设备组成；该中央控制***控制着整个轨道上所有工位的工作节拍(即、是否流转到下一个工位，何时流转到下一个工位，每个工位的工作时间为多久
等等)，当中央控制***接收到每个工位的工作完成信息后，控制整个工作***进行工位之间的流转操作。In this embodiment, the central control system is composed of devices including sensors, signal conversion controllers, software, and DCS modules; the central control system controls the working tempo of all stations on the entire track (ie, whether it flows to the next work) Bit, when is the flow to the next station, how long is the working time of each station?
Etc.), when the central control system receives the work completion information of each station, it controls the entire working system to perform the flow operation between the stations.
本发明涉及的具体工艺如下：The specific process involved in the present invention is as follows:
步骤一：不同型号模型通过牵引设备让其流动到放张工位1或2对产品进行放张作业；Step 1: Different models are allowed to flow to the release station 1 or 2 through the traction device;
步骤二：模型进入脱模工位3或4，将产品从模型中顶出。Step 2: The model enters the demolding station 3 or 4 to eject the product from the model.
步骤三：模型进入清理工位5，用设备对模型进行清理、喷涂隔离剂。Step 3: The model enters the cleaning station 5, and the model is used to clean the model and spray the release agent.
步骤四：模型进入工位6，将产品预埋件首先进行安装。Step 4: The model enters station 6, and the product embedded parts are first installed.
步骤五：模型进入工位7，钢筋笼入模。Step 5: The model enters station 7, and the steel cage enters the mold.
步骤六：模型进入工位8或9，用连接杆对预应力钢筋进行连接。Step 6: The model enters station 8 or 9 and connects the prestressed steel bars with connecting rods.
步骤七：模型进入工位10，用仪器对钢筋笼的绝缘状况进行检测。Step 7: The model enters the station 10, and the insulation condition of the steel cage is detected by the instrument.
步骤八：模型进入工位11或12，用张拉设备对预应力钢筋进行张拉。Step 8: The model enters station 11 or 12 and tensions the prestressed steel bars with tensioning equipment.
步骤九：模型进入工位13，用激光三维扫描仪对模型尺寸进行检测。Step 9: The model enters the station 13 and the model size is detected by a laser three-dimensional scanner.
步骤十：模型进入工位14，灌注混凝土并振捣。Step 10: The model enters station 14, injecting concrete and vibrating.
步骤十一：模型进入工位15，清理模型表面。Step 11: The model enters station 15 to clean the surface of the model.
步骤十二：模型进入工位16，摆渡车将模型送入到养生区。Step 12: The model enters station 16, and the shuttle bus delivers the model to the health area.
步骤十三：模型进入工位17，通过喷水雾的方式控制温度和湿度养生。Step 13: The model enters station 17, and the temperature and humidity are controlled by spraying water mist.
步骤十四：模型进入工位18，对产品按照技术条件要求升温。Step 14: The model enters the station 18 and heats up the product according to the technical requirements.
步骤十五：模型进入工位19，对产品按照技术条件要求恒温。Step 15: The model enters the station 19 and the temperature is constant according to the technical requirements.
步骤十六：模型进入工位20，对产品按照技术条件要求降温。Step 16: The model enters the station 20 and cools the product according to the technical requirements.
步骤十七：模型进入工位21，通过摆渡车让产品进入放张工位，如此循环，完成产品的流水线自动控制生产。
Step 17: The model enters the station 21, and the product is put into the release station through the shuttle bus. This cycle, the production line of the product is automatically controlled and produced.
本实施例的变形例一： Modification 1 of this embodiment:
针对不同的工艺，可采用不同种类的设备来进行，组合方式不同而产生的同样流水线生产方式。For different processes, different types of equipment can be used, and the same pipeline production method is produced by different combinations.
本实施例的变形例二：Modification 2 of this embodiment:
针对不同的工艺，可通过增加或减少工艺步骤而产生同样流水线生产方式。
The same pipeline production method can be produced by increasing or decreasing process steps for different processes.
Claims (10)
- 一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：包含至少一条流水线轨道和至少一个模型；An automated manufacturing technology for a pretensioned prestressed concrete track slab unit assembly line, characterized in that it comprises at least one pipeline track and at least one model;所述流水线轨道上设有若干工位；a plurality of stations are arranged on the pipeline track;所述模型在模型流转机构的作用下，按照时间节拍，在流水线轨道上的各工位间进行流转；The model is flowed between the stations on the pipeline track according to the time tempo under the action of the model flow mechanism;其中，所述时间节拍为每个工位的工作时间。Wherein, the time beat is the working time of each station.
- 如权利要求1所述的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：The assembly line automatic manufacturing technology of a pretensioned prestressed concrete track plate unit according to claim 1, wherein:所述工位上均设有传感器；The workstation is provided with sensors;所述传感器将各工位上相应工作的完成状态和完成质量的信号传输到中央控制***；The sensor transmits a signal of completion status and quality of completion of the corresponding work at each station to the central control system;所述中央控制***根据上述信号，控制整个***运转的时间节拍。The central control system controls the time tempo of the entire system operation based on the above signals.
- 如权利要求1所述的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：The assembly line automatic manufacturing technology of a pretensioned prestressed concrete track plate unit according to claim 1, wherein:所述模型流转机构包括牵引***、行程开关、信号转换控制器、控制***组成；The model flow mechanism comprises a traction system, a travel switch, a signal conversion controller, and a control system;所述牵引***、行程开关、信号转换控制器、控制***之间电气连接。Electrical connection between the traction system, the travel switch, the signal conversion controller, and the control system.
- 如权利要求1所述的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：The assembly line automatic manufacturing technology of a pretensioned prestressed concrete track plate unit according to claim 1, wherein:所述工位包括沿模型流动的方向依次设置的放张工位、脱模工位、模型清理和脱模剂喷洒及风干工位、预埋件安装工位、钢筋笼入模工位、预应力钢筋连接 工位、绝缘检测工位、预应力钢筋张拉工位、模型变形检测工位、混凝土布料及振捣工位、模型表面清理工位、模型摆渡工位一、喷雾养生工位、升温工位、恒温工位、降温工位、模型摆渡工位二；The work station includes a laying station, a demolding station, a model cleaning and a mold release agent spraying and air drying station, a pre-embedded part mounting station, a steel cage mold-injecting station, and a pre-set position along the direction of the flow of the model. Stress reinforcement connection Work station, insulation inspection station, prestressed steel tension station, model deformation inspection station, concrete fabric and vibrating station, model surface cleaning station, model ferry station, spray health station, heating station , constant temperature station, cooling station, model ferry station 2;其中，各所述工位在流水线轨道上的设置数量为一个或一个以上；Wherein, the number of each of the stations is set on the pipeline track is one or more;所述流水线轨道呈环形结构；The pipeline track has a ring structure;所述各工位沿模型流动的方向依次设置在流水线轨道上。The stations are sequentially disposed on the pipeline track in the direction in which the model flows.
- 如权利要求4所述的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：The assembly line automatic manufacturing technology of a pretensioned prestressed concrete track plate unit according to claim 4, wherein:当模型流转到预应力钢筋张拉工位后，由模型来承受预应力钢筋的张拉应力。After the model flows to the prestressed steel tensioning station, the tensile stress of the prestressed steel is absorbed by the model.
- 如权利要求4所述的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：The assembly line automatic manufacturing technology of a pretensioned prestressed concrete track plate unit according to claim 4, wherein:当模型流转到放张工位后，通过电动扭转的方式来卸出张拉应力。When the model flow is transferred to the release station, the tensile stress is discharged by electric torsion.
- 如权利要求4所述的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：The assembly line automatic manufacturing technology of a pretensioned prestressed concrete track plate unit according to claim 4, wherein:所述中央控制***由包括传感器、信号转换控制器、软件、DCS模块的设备组成；所述放张工位上设有放张设备组件；The central control system is composed of a device including a sensor, a signal conversion controller, a software, and a DCS module; and the release device is provided with a release device component;所述放张设备组件包括棘轮咬合头、传动齿轮组、伺服电机、位移计、滑动槽、千斤顶、信号转换控制器；The tensioning device assembly comprises a ratchet biting head, a transmission gear set, a servo motor, a displacement meter, a sliding slot, a jack, and a signal conversion controller;所述脱模工位上设有脱模设备组件；a demoulding device assembly is disposed on the demolding station;所述脱模设备组件包括千斤顶、位移计、信号转换控制器； The demoulding device assembly includes a jack, a displacement meter, and a signal conversion controller;所述模型清理和脱模剂喷洒及风干工位上设有模型清理设备组件、脱模剂喷涂设备组件和风干设备组件；The model cleaning and release agent spraying and air drying station is provided with a model cleaning device component, a release agent spraying device component and an air drying device component;所述模型清理设备组件包括电动刷、滑动槽、吸尘器、行程开关、信号转换控制器；The model cleaning device component includes an electric brush, a sliding slot, a vacuum cleaner, a travel switch, and a signal conversion controller;所述脱模剂喷涂设备组件包括喷雾器、滑动槽、行程开关，信号转换控制器；The mold release agent spraying device assembly includes a sprayer, a sliding groove, a stroke switch, and a signal conversion controller;所述风干设备组件包括热风机，喷嘴，滑动槽，行程开关，信号转换控制器；所述钢筋笼入模工位上设有钢筋入模设备组件；The air drying equipment component comprises a hot air blower, a nozzle, a sliding slot, a travel switch, and a signal conversion controller; and the steel cage injecting mold station is provided with a steel bar die-injecting device component;所述钢筋入模设备组件包括行车、吊装工具；The reinforcing steel die-injecting device assembly comprises a driving and lifting tool;所述预应力钢筋连接工位上设有连接设备组件；The prestressed steel bar connection station is provided with a connecting device component;所述连接设备组件包括夹具，气动扭力扳手，信号转换控制器；The connecting device component includes a clamp, a pneumatic torque wrench, and a signal conversion controller;所述预应力钢筋张拉工位上设有张拉设备组件；The tensioning steel bar tensioning station is provided with a tensioning device assembly;所述张拉设备组件包括定位顶升/下降千斤顶、U型力爪、千斤顶、测力传感器、位移传感器、油泵、控制***和楔形块、气动缸、信号转换控制器；The tensioning device assembly includes a positioning jacking/lowering jack, a U-shaped force claw, a jack, a load cell, a displacement sensor, an oil pump, a control system and a wedge block, a pneumatic cylinder, and a signal conversion controller;所述混凝土布料及振捣工位上设有振捣设备组件、布料设备组件和送料设备组件；The concrete cloth and the vibrating station are provided with a vibrating device component, a cloth device component and a feeding device component;所述振捣设备组件包括两分块刚性支架、振动电机、控制器组成振捣设备；The vibrating device assembly comprises a two-part rigid support, a vibration motor and a controller to form a vibrating device;所述布料设备组件包括料斗、底部液压开合门、附着式振捣电机、滑动槽、行程开关、信号转换控制器；The cloth equipment component comprises a hopper, a bottom hydraulic opening and closing door, an attached vibrating motor, a sliding slot, a stroke switch, and a signal conversion controller;所述送料设备组件包括混凝土搅拌站、料斗、导轨、电动平车、信号转换控制器；The feeding device assembly comprises a concrete mixing station, a hopper, a guide rail, an electric flat car, and a signal conversion controller;所述喷雾养生工位包括养护设备组件；The spray health station includes a maintenance equipment component;所述养护设备组件包括养护罩、喷雾器、温度计、湿度计、锅炉、分压器、分隔门或风幕、信号转换控制器； The maintenance equipment assembly includes a maintenance cover, a sprayer, a thermometer, a hygrometer, a boiler, a voltage divider, a partition door or a wind curtain, and a signal conversion controller;所述绝缘检测工位和模型变形检测工位上设有检测设备组件；a detection device component is disposed on the insulation detecting station and the model deformation detecting station;所述检测设备组件包括激光扫描器、滑动槽、行程开关、三维照拍***、信息检测转换***、单板机及相应软件。The detecting device component comprises a laser scanner, a sliding slot, a travel switch, a three-dimensional photographing system, an information detection conversion system, a single board machine and corresponding software.
- 如权利要求1-7任一所述的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：The assembly line automatic manufacturing technology of a pretensioned prestressed concrete track plate unit according to any one of claims 1-7, characterized in that:所述流水线轨道上还设有身份识别工位；An identification station is also disposed on the pipeline track;还包括依次设置的成品翻转工位、成品封锚工位、成品板检测工位；It also includes a finished product reversing station, a finished sealing station, and a finished board inspection station.当轨道板完成脱模后，所述轨道板依次在成品翻转工位、成品封锚工位、成品板检测工位间进行流转。After the track plate is demolded, the track plate is sequentially flowed between the finished product turning station, the finished sealing station, and the finished board detecting station.
- 如权利要求8所述的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于：The assembly line automatic manufacturing technology of a pretensioned prestressed concrete track slab unit according to claim 8 is characterized in that:所述成品翻转工位上设有成品翻转设备组件；The finished product inverting station is provided with a finished turning device component;所述成品翻转设备组件包括行车、吊装工具；The finished turning equipment component comprises a driving and lifting tool;所述成品封锚工位上设有封锚设备组件；The sealing and anchoring device assembly is arranged on the finished sealing and anchoring station;所述封锚设备组件由搅拌机、填压机；The anchoring device assembly is composed of a mixer and a filling machine;所述成品板检测工位上设有成品板检测设备组件；The finished board detecting station is provided with a finished board detecting device component;所述成品板检测设备组件包括激光扫描器、滑动槽、行程开关、三维照拍***、信息检测转换***、单板机及相应软件。The finished board detecting device component comprises a laser scanner, a sliding slot, a travel switch, a three-dimensional photographing system, an information detection conversion system, a single board machine and corresponding software.
- 如权利要求1-9任一所述的一种先张法预应力混凝土轨道板机组流水线自动化制造技术，其特征在于，由如下工艺步骤来实现： The assembly line automatic manufacturing technology of a pretensioned prestressed concrete track plate unit according to any one of claims 1-9, characterized in that the following process steps are implemented:步骤一：不同型号模型通过模型流转机构流动到放张工位，对产品进行放张作业；Step 1: Different model models flow through the model transfer mechanism to the release station to perform the release operation of the product;步骤二：模型进入脱模工位，将产品从模型中顶出；Step 2: The model enters the demolding station and the product is ejected from the model;步骤三：模型进入模型清理和脱模剂喷洒及风干工位，对模型进行清理、喷涂隔离剂的工序；Step 3: The model enters the process of model cleaning and release agent spraying and air drying station, and the process of cleaning and spraying the release agent on the model;步骤四：模型进入预埋件安装工位，将产品预埋件进行安装；Step 4: The model enters the embedded parts installation station to install the embedded parts of the product;步骤五：模型进入钢筋笼入模工位，将钢筋笼入模；Step 5: The model enters the steel cage into the mold station, and the steel cage is inserted into the mold;步骤六：模型进入预应力钢筋连接工位，用连接杆对预应力钢筋进行连接；Step 6: The model enters the prestressed steel connection station, and the prestressed steel bars are connected by the connecting rod;步骤七：模型进入绝缘检测工位，对钢筋笼的绝缘状况进行检测；Step 7: The model enters the insulation inspection station to detect the insulation condition of the steel cage;步骤八：模型进入预应力钢筋张拉工位，用张拉设备对预应力钢筋进行张拉；Step 8: The model enters the prestressed steel tensioning station, and the tensioning steel bar is tensioned by the tensioning device;步骤九：模型进入模型变形检测工位，用激光三维扫描仪对模型尺寸进行检测；Step 9: The model enters the model deformation detection station, and the model size is detected by a laser three-dimensional scanner;步骤十：模型进入混凝土布料及振捣工位，灌注混凝土并振捣；Step 10: The model enters the concrete fabric and vibrating station, injects concrete and vibrates;步骤十一：模型进入模型表面清理工位，进行模型的表面清洗；Step 11: The model enters the surface cleaning station of the model to perform surface cleaning of the model;步骤十二：模型进入模型摆渡工位一，通过摆渡设备将模型送入到养生区；Step 12: The model enters the model ferry station, and the model is sent to the health area through the ferry equipment;步骤十三：模型进入喷雾养生工位，通过喷水雾的方式控制温度和湿度养生；Step 13: The model enters the spray health station to control temperature and humidity by spraying water mist;步骤十四：模型进入升温工位，按照技术条件要求进行升温；Step 14: The model enters the heating station and heats up according to the technical requirements;步骤十五：模型进入恒温工位，按照技术条件要求进行恒温；Step 15: The model enters a constant temperature station and is thermostated according to technical requirements;步骤十六：模型进入降温工位，按照技术条件要求进行降温；Step 16: The model enters the cooling station and is cooled according to the technical requirements;步骤十七：模型进入模型摆渡工位二，通过摆渡设备让带有产品的模型进入放张工位。 Step 17: The model enters the model ferry station 2, and the model with the product enters the release station through the ferry device.
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Also Published As
| Publication number | Publication date |
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| CN106466882A (en) | 2017-03-01 |
| RU2693792C1 (en) | 2019-07-04 |
| CN106466882B (en) | 2019-02-01 |
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