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路基预制电缆槽脱模工装
路基预制电缆槽脱模工装
Subgrade prefabricated cable trough demoulding tooling
在高速铁路路基电缆槽预制施工过程中，因其重量较重，壁厚较薄，常规倒扣脱模方式费时费力，效率低下且容易造成模具（ABS）破损、槽底断裂、缺边掉角等现象。
In the process of precast construction of subgrade cable groove in high speed railway, because of its heavy weight and thin wall thickness, the conventional way of falling out of die is time-consuming, inefficient and easy to cause the breakage of the die (ABS), the fracture of the bottom of the groove and the corner missing angle.
1目的及思路
1 aims and ideas
通过改变脱模方式，制作相应工装，尽量使用机械替代人工，提高施工效率，缩短施工工期，提高产品合格率，降低施工成本。
By changing the mode of demoulding, the corresponding tooling is made and mechanical replacement is used as much as possible. The construction efficiency is improved, the construction time is shortened, the qualified rate of the product is improved and the cost of construction is reduced.
2工作原理
2 working principle
1. 预埋钢筋挂钩：
1. pre buried steel bar hook:
在进行电缆槽钢筋笼焊接时，用φ6的制作钢筋弯钩，焊接在侧面钢筋笼中间位置。
During the welding of the cage cage, the steel cobweb with a diameter of 6 is welded to the middle position of the side reinforcement cage.
2. 电缆槽脱模工装：
2. cable groove demoulding tooling:
路基电缆槽脱模工装有φ50的钢管焊接而成，宽1m，长度根据不同的电缆槽型号进行调整，在距离地面60cm位置设置钢管横梁和用槽钢做的移动限位挡板，并在底部安装4个万向轮以便移动。用钢丝绳挂钩与预埋钢筋连接通过顶部的卷扬机进行提升，提升至限位挡板位置时移动挡板对准电缆槽模具边沿，通过卷扬机提升力以及敲击振动使电缆槽和模具垂直脱离。如下图所示：
The subgrade cable groove die worker is fitted with a 50 steel pipe, with a width of 1m, the length is adjusted according to the different type of cable slot, the steel pipe cross beam and the channel steel moving limit baffle are set at the ground 60cm position, and the 4 universal wheel is installed at the bottom to move. The wire rope hooks are connected with the preburied steel bar to be hoisted through the top roll hoist, and the moving baffle is aligned with the edge of the cable groove at the position of the limit baffle. The cable slot and the die are separated vertically through the lifting force of the hoist and the knocking vibration. As shown in the following figure:
预制电缆槽脱模工装
Prefabricated cable grooves demoulding
3创新点和技术难度
3 innovation point and technical difficulty
1.彻底改变传统倒扣脱模方式。
1. completely change the traditional way of falling out of mold.
2.槽体焊接挂钩，卷扬机提升，限位挡板精确卡位，辅以敲击振动，使其模具与槽体垂直脱离。
2. slot welding hooks, hoist lifting, limit baffle accurate card, supplemented by percussion vibration, so that its die and tank vertical separation.
3.创新脱模工装，利用现有成熟技术，综合而成，技术难度不大。
3. the innovative release tooling is made up of the existing mature technology.
4实施效果
4 implementation effect
项目部采用电缆槽脱模工装后大大的降低了人工劳动强度，提高了施工效率、降低了模具及成品的破损率，获得了业主及监理单位的一致好评，并由成贵公司组织全线推广应用，成为了成贵线各标段预制构件场电缆槽施工的标配，各标段使用后，反映均取得了较好的效果。
The project department greatly reduced the labor intensity, improved the construction efficiency, reduced the breakage rate of the mould and finished products, and obtained the praise of the owner and the supervision unit. The project department has been popularized and applied by the Chenggui company, and has become the standard of the construction of the cable groove in the prefabricated component field of each section of the Chenggui line. After the use of each bid, the reflection has achieved good results.
电缆槽脱模工装实施效果图
Implementation effect diagram of cable grooves demoulding tooling
✪ 经济效益 ✪
Economic benefit
我项目部共生产各类电缆槽24408块，采用电缆槽脱模支架之后，极大地提升了电缆槽脱模效率，平均每块电缆槽脱模时间节省约3分钟，缩短工期50余天，为项目部节省成本约10万元。使用电缆槽脱模工装后，电缆槽不合格产品率降低了月5%，为项目部节省成本6万余元，使用电缆槽脱模支架尅以避免原脱模方法对于电缆槽模具的损坏，提高模具的周转率，节省模具费用约1万元，累计为项目部节省成本17万余元。
24408 pieces of cable grooves were produced in our project department. After using the cable slot stripping bracket, the release efficiency of the cable groove was greatly improved. The average time saving of each cable slot was saved about 3 minutes, the time limit of the project was shortened by 50 Yu Tian, and the cost of the project Department was saved about 100 thousand yuan. The unqualified product rate of the cable trough is reduced by 5%, and the cost of the cable trough is reduced by 6 million yuan. The cable trough removal support is used to avoid the damage to the cable groove mold, improve the turnover rate of the die and save the die cost about 10 thousand yuan, and save more than 17 million cost for the project department. Yuan.
✪ 社会效益✪
Social benefit
使用了电缆槽脱模支架后，大大地降低了作业工人的劳动强度，提高了施工效率、缩短工期。我项目部使用后获得业主及监理单位的一致好评，先后获得了2次“绿牌”奖励。2016年3月底，成贵公司组织成贵线四川段16家施工单位及8家监理单位莅临我不观摩学习并在全线推广应用，成为了成贵线各标段预制构件厂电缆槽施工的标配，各标段使用后，均取得了较好的效果。
After using the cable groove demoulding bracket, the labor intensity of the workers is greatly reduced, the construction efficiency is improved, and the construction period is shortened. After the use of the project department, I received the praise from the owner and the supervision unit, and I got 2 "green card" awards. At the end of March 2016, the 16 construction units and 8 supervision units of Sichuan section of your company, which are organized into your line, come to me to learn and popularize it on the whole line. It has become a mark for the construction of cable grooves in the prefabricated component factory of the Chenggui line. After the use of each section, it has achieved good results.
Subgrade prefabricated cable trough demoulding tooling
在高速铁路路基电缆槽预制施工过程中，因其重量较重，壁厚较薄，常规倒扣脱模方式费时费力，效率低下且容易造成模具（ABS）破损、槽底断裂、缺边掉角等现象。
In the process of precast construction of subgrade cable groove in high speed railway, because of its heavy weight and thin wall thickness, the conventional way of falling out of die is time-consuming, inefficient and easy to cause the breakage of the die (ABS), the fracture of the bottom of the groove and the corner missing angle.
1目的及思路
1 aims and ideas
通过改变脱模方式，制作相应工装，尽量使用机械替代人工，提高施工效率，缩短施工工期，提高产品合格率，降低施工成本。
By changing the mode of demoulding, the corresponding tooling is made and mechanical replacement is used as much as possible. The construction efficiency is improved, the construction time is shortened, the qualified rate of the product is improved and the cost of construction is reduced.
2工作原理
2 working principle
1. 预埋钢筋挂钩：
1. pre buried steel bar hook:
在进行电缆槽钢筋笼焊接时，用φ6的制作钢筋弯钩，焊接在侧面钢筋笼中间位置。
During the welding of the cage cage, the steel cobweb with a diameter of 6 is welded to the middle position of the side reinforcement cage.
2. 电缆槽脱模工装：
2. cable groove demoulding tooling:
路基电缆槽脱模工装有φ50的钢管焊接而成，宽1m，长度根据不同的电缆槽型号进行调整，在距离地面60cm位置设置钢管横梁和用槽钢做的移动限位挡板，并在底部安装4个万向轮以便移动。用钢丝绳挂钩与预埋钢筋连接通过顶部的卷扬机进行提升，提升至限位挡板位置时移动挡板对准电缆槽模具边沿，通过卷扬机提升力以及敲击振动使电缆槽和模具垂直脱离。如下图所示：
The subgrade cable groove die worker is fitted with a 50 steel pipe, with a width of 1m, the length is adjusted according to the different type of cable slot, the steel pipe cross beam and the channel steel moving limit baffle are set at the ground 60cm position, and the 4 universal wheel is installed at the bottom to move. The wire rope hooks are connected with the preburied steel bar to be hoisted through the top roll hoist, and the moving baffle is aligned with the edge of the cable groove at the position of the limit baffle. The cable slot and the die are separated vertically through the lifting force of the hoist and the knocking vibration. As shown in the following figure:
预制电缆槽脱模工装
Prefabricated cable grooves demoulding
3创新点和技术难度
3 innovation point and technical difficulty
1.彻底改变传统倒扣脱模方式。
1. completely change the traditional way of falling out of mold.
2.槽体焊接挂钩，卷扬机提升，限位挡板精确卡位，辅以敲击振动，使其模具与槽体垂直脱离。
2. slot welding hooks, hoist lifting, limit baffle accurate card, supplemented by percussion vibration, so that its die and tank vertical separation.
3.创新脱模工装，利用现有成熟技术，综合而成，技术难度不大。
3. the innovative release tooling is made up of the existing mature technology.
4实施效果
4 implementation effect
项目部采用电缆槽脱模工装后大大的降低了人工劳动强度，提高了施工效率、降低了模具及成品的破损率，获得了业主及监理单位的一致好评，并由成贵公司组织全线推广应用，成为了成贵线各标段预制构件场电缆槽施工的标配，各标段使用后，反映均取得了较好的效果。
The project department greatly reduced the labor intensity, improved the construction efficiency, reduced the breakage rate of the mould and finished products, and obtained the praise of the owner and the supervision unit. The project department has been popularized and applied by the Chenggui company, and has become the standard of the construction of the cable groove in the prefabricated component field of each section of the Chenggui line. After the use of each bid, the reflection has achieved good results.
电缆槽脱模工装实施效果图
Implementation effect diagram of cable grooves demoulding tooling
✪ 经济效益 ✪
Economic benefit
我项目部共生产各类电缆槽24408块，采用电缆槽脱模支架之后，极大地提升了电缆槽脱模效率，平均每块电缆槽脱模时间节省约3分钟，缩短工期50余天，为项目部节省成本约10万元。使用电缆槽脱模工装后，电缆槽不合格产品率降低了月5%，为项目部节省成本6万余元，使用电缆槽脱模支架尅以避免原脱模方法对于电缆槽模具的损坏，提高模具的周转率，节省模具费用约1万元，累计为项目部节省成本17万余元。
24408 pieces of cable grooves were produced in our project department. After using the cable slot stripping bracket, the release efficiency of the cable groove was greatly improved. The average time saving of each cable slot was saved about 3 minutes, the time limit of the project was shortened by 50 Yu Tian, and the cost of the project Department was saved about 100 thousand yuan. The unqualified product rate of the cable trough is reduced by 5%, and the cost of the cable trough is reduced by 6 million yuan. The cable trough removal support is used to avoid the damage to the cable groove mold, improve the turnover rate of the die and save the die cost about 10 thousand yuan, and save more than 17 million cost for the project department. Yuan.
✪ 社会效益✪
Social benefit
使用了电缆槽脱模支架后，大大地降低了作业工人的劳动强度，提高了施工效率、缩短工期。我项目部使用后获得业主及监理单位的一致好评，先后获得了2次“绿牌”奖励。2016年3月底，成贵公司组织成贵线四川段16家施工单位及8家监理单位莅临我不观摩学习并在全线推广应用，成为了成贵线各标段预制构件厂电缆槽施工的标配，各标段使用后，均取得了较好的效果。
After using the cable groove demoulding bracket, the labor intensity of the workers is greatly reduced, the construction efficiency is improved, and the construction period is shortened. After the use of the project department, I received the praise from the owner and the supervision unit, and I got 2 "green card" awards. At the end of March 2016, the 16 construction units and 8 supervision units of Sichuan section of your company, which are organized into your line, come to me to learn and popularize it on the whole line. It has become a mark for the construction of cable grooves in the prefabricated component factory of the Chenggui line. After the use of each section, it has achieved good results.
