Real-time dynamic monitoring device for specific gravity of cement grout

Abstract

The invention relates to a real-time dynamic monitoring device for the specific gravity of cement slurry. The real-time dynamic monitoring device comprises a cement slurry storage tank, a slurry specific gravity collecting device, an integrated controller, a data wireless transmitting device, a database and application server, slurry specific gravity monitoring machine-mounted end equipment and slurry specific gravity monitoring remote monitoring end equipment, the slurry specific gravity collecting device is installed at a proper position of a cement slurry stirring tank or a cement slurry storage tank, and the slurry specific gravity collecting device, the integrated controller, the data wireless transmitting device, the database and application server and the slurry specific gravity monitoring remote monitoring end equipment are sequentially connected. And the integrated controller is also connected to the slurry specific gravity monitoring machine upper-end equipment. According to the invention, real-time measurement of the specific gravity of the slurry can be realized, measurement information can be remotely sent to a database for subsequent quality evaluation application, pile forming is ensured to meet design requirements, real-time alarm is carried out on substandard conditions, and a statistical chart is formed to serve as a basis for quality management of related departments.

Description

Technical Field

[0001] The invention belongs to the technical field of building material detection, and in particular relates to a real-time dynamic monitoring device for the specific gravity of cement slurry. Background Art

[0002] In construction projects, the specific gravity of cement slurry plays a crucial role in project quality. For example, in bored pile construction, underground continuous wall casting, and anti-seepage wall construction, the accuracy of cement slurry specific gravity directly affects the strength and durability of the concrete, as well as the overall stability of the project. Accurate specific gravity ensures that the cement slurry evenly fills the wall space during the pouring process, forming a dense structure that effectively transmits and disperses stress, enhancing the durability and overall stability of the wall and avoiding potential safety hazards caused by wall quality issues.

[0003] Traditional sensors are prone to clogging in environments with high particle content in cement slurries and are subject to interference from mixing vibrations and pipeline pulses, resulting in large data fluctuations and low reliability. During cast-in-place pile construction, slurry flow rate fluctuations or impurity accumulation can significantly affect sensor accuracy. Mechanical vibrations from the mixing equipment can cause signal drift, resulting in measurement errors of up to ±2%. Furthermore, existing cement slurry specific gravity testing mostly relies on manual sampling followed by measurement using a hydrometer. This method is not only cumbersome and inefficient, but also lacks real-time monitoring, making it difficult to meet the construction project's requirements for precise cement slurry quality control and efficient construction. Furthermore, manual testing is susceptible to human factors (for example, the specific gravity of cement slurry may change between sampling due to fluctuations in raw material properties, changes in mixing equipment operating conditions, or adjustments to construction processes, which can be difficult for construction workers to detect and respond to in a timely manner). This can lead to deviations in the accuracy and reliability of measurement results.

[0004] Therefore, developing an intelligent specific gravity collection device with real-time monitoring, anti-blocking and anti-vibration capabilities is one of the key issues that need to be urgently addressed in the field of construction engineering technology. Summary of the Invention

[0005] The purpose of the present invention is to overcome the shortcomings of the existing technology and provide a real-time dynamic monitoring device for the specific gravity of cement slurry. Through the structural design of the anti-blocking protective cover and the anti-vibration bracket and the dynamic algorithm optimization, the industry pain points of traditional devices are overcome, and a real-time dynamic device is developed to monitor the specific gravity of cement slurry, which has important practical significance for improving the quality control level of construction projects and ensuring the safety and stability of projects.

[0006] The present invention solves the technical problem by the following technical solutions:

[0007] A real-time dynamic monitoring device for cement slurry specific gravity includes a cement mud storage tank, a slurry specific gravity acquisition device, an integrated controller, a data wireless transmission device, a database and application server, a slurry specific gravity monitoring airborne terminal device, and a slurry specific gravity monitoring remote monitoring terminal device; the slurry specific gravity acquisition device is installed on a cement slurry mixing tank or a cement mud storage tank, the slurry specific gravity acquisition device, the integrated controller, the data wireless transmission device, the database and application server and the slurry specific gravity monitoring remote monitoring terminal device are connected in sequence, and the integrated controller is also connected to the slurry specific gravity monitoring airborne terminal device.

[0008] Furthermore, the slurry specific gravity acquisition device includes a dual pressure sensor group, an anti-clogging protective cover, an anti-vibration bracket, and an LCD display screen. The dual pressure sensor group is fixed to the cement slurry storage tank with a vertical spacing of Δh = 300mm ± 5mm and is threadedly connected above and below the measuring rod. The dual pressure sensor group calculates the slurry density in real time by measuring the pressure difference between the two points.

[0009] The anti-clogging protective cover is a conical porous stainless steel filter structure, covering the sensor probe surface of the dual pressure sensor group. The porous aperture of the anti-clogging protective cover is 0.5mm, and the conical taper is 45°. When installed, the anti-clogging protective cover is arranged in a countercurrent layout with the slurry flow direction, intercepting large particles of impurities and using fluid flushing to achieve self-cleaning, thereby preventing sensor clogging;

[0010] The anti-vibration bracket consists of a spring damper and a flange. The main body of the anti-vibration bracket is rigidly connected to the outer wall through the flange. The dual pressure sensor group is suspended inside the anti-vibration bracket through the spring damper to absorb the vibration of the mixing tank and the pulse impact of the pipeline, ensuring the stability of pressure signal acquisition;

[0011] The LCD display is embedded in the operation panel on the outside of the conveying pipeline, displays the current specific gravity value and historical trend curve in real time, and integrates touch buttons for manual calibration settings.

[0012] Moreover, the integrated controller includes a 12V regulated power supply and a data controller. The 12V regulated power supply supplies power to the data controller and the slurry specific gravity acquisition device. The data controller receives the specific gravity data transmitted by the slurry specific gravity acquisition device in real time and transmits it to the data wireless sending device through the port.

[0013] Moreover, the data wireless transmission module sends the current measurement time and its corresponding slurry specific gravity sent by the integrated controller to the database and application server via the 4G or 5G network for subsequent use.

[0014] Moreover, the database and application server receive and store the current measurement time and its corresponding slurry density data information sent from the data wireless transmission module, and judge whether the current slurry density meets the standard based on the slurry density control standard input by the slurry density monitoring remote monitoring terminal device. If not, an alarm is sent to the slurry density monitoring airborne terminal device through the 4G or 5G network to remind the construction personnel to make adjustments, and the information is recorded in the slurry density monitoring remote monitoring terminal device.

[0015] Moreover, the slurry specific gravity monitoring airborne terminal device is installed near the cement slurry mixing tank at the back end of the pulping station, and is connected to the data controller of the integrated controller via a data cable. It displays the current measurement time and the corresponding slurry specific gravity transmitted by the data controller in real time. The construction personnel at the back end of the pulping station can adjust the working parameters of the cement slurry to the set requirements in time according to the displayed information.

[0016] Moreover, the slurry specific gravity monitoring remote monitoring terminal device is installed on a PC or mobile laptop that can be connected to the Internet at the construction site. Before the monitoring begins, the control standard of the slurry specific gravity is set through the monitoring terminal; then, it is stored in the database and application server through the Internet; during the monitoring process, the client can display the specific gravity of each tank of cement slurry in real time, and can query and output the monitoring results; at the same time, it receives the alarm information sent by the database and application server that the slurry specific gravity does not meet the standard, prompting the on-site quality management personnel to make timely adjustments to meet the design requirements.

[0017] The advantages and beneficial effects of the present invention are:

[0018] 1. Dual pressure sensor group and anti-interference structure design: The dual pressure sensor group is fixed in an appropriate position with a vertical spacing of Δh = 300mm ± 5mm. Combined with an anti-clogging protective cover (conical counterflow filter) and an anti-vibration bracket (spring damping structure), it eliminates interference with measurement caused by slurry flow impact, impurity blockage and equipment vibration, ensuring the stability of pressure signal acquisition.

[0019] 2. Aiming at the special working conditions of direct monitoring in cement slurry tanks, the present invention proposes a stirring disturbance correction formula. Through stirring experiments and error comparison, it is proved that the dynamic accuracy is improved by more than 70%.

[0020] 3. Real-time measurement and data transmission: A slurry specific gravity acquisition device installed on the cement slurry mixing tank or storage tank conveying pipeline is used to monitor the slurry specific gravity in real time based on the principle of a differential pressure density meter. The data is transmitted to the integrated controller in real time or at a fixed time, and then remotely sent to the database and application server via the 4G or 5G network via a data wireless transmission device, realizing real-time measurement and remote data transmission.

[0021] 4. Data analysis and alarm: The analysis module of the database and application server compares the real-time measured slurry density with the preset control standard. If it does not meet the standard, the information feedback module will send an alarm to the slurry density monitoring airborne terminal device and remote monitoring terminal device via the 4G or 5G network to remind construction personnel to make adjustments.

[0022] 5. Multi-terminal display and operation: The onboard terminal device for slurry density monitoring is installed near the mixing tank at the back of the pulping station, and displays the slurry density data in real time, making it convenient for construction personnel to adjust working parameters; the remote monitoring terminal device can set the density control standard, display the slurry density of each tank in real time, and query and output monitoring results, making it easier for quality management personnel to control quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a schematic diagram of the real-time dynamic monitoring device of the present invention;

[0024] Figure 2 It is a structural schematic diagram of the present invention.

[0025] Description of reference numerals:

[0026] 1. Cement slurry storage tank; 2. Slurry specific gravity acquisition device, including 2-1 dual pressure sensor group, 2-2 anti-blocking protective cover, 2-3 anti-vibration bracket, 2-4 LCD display; 3. Integrated controller; 4. Data wireless transmission unit (DTU); 5. Database and application server; 6. Slurry specific gravity monitoring airborne terminal device; 7. Slurry specific gravity monitoring remote monitoring terminal device. DETAILED DESCRIPTION

[0027] The present invention will be further described in detail below through specific examples. The following examples are only illustrative and not restrictive, and the scope of protection of the present invention cannot be limited thereto.

[0028] like Figure 1 、 2 As shown, an embodiment of the present invention provides a real-time dynamic monitoring device for cement slurry specific gravity, including: a slurry specific gravity acquisition device 2, an integrated controller 3, a data wireless transmission device (DTU) 4, a database and application server 5, a slurry specific gravity monitoring airborne terminal device 6, and a slurry specific gravity monitoring remote monitoring terminal device 7.

[0029] (1) Slurry specific gravity collection device

[0030] The slurry specific gravity collection device includes a dual pressure sensor group 2-1, an anti-clogging protective cover 2-2, an anti-vibration bracket 2-3 and an LCD display 2-4, which are installed at a suitable position of the cement slurry mixing tank to ensure that the probe can fully contact the cement slurry. When the cement slurry flows into the storage tank after stirring, the slurry specific gravity is monitored in real time according to the principle of fluid statics, and the monitored specific gravity value is sent to the data controller in real time or periodically.

[0031] In order to ensure the stability of the device, an anti-vibration bracket is used to fix it, and an anti-clogging protective cover is used to encapsulate the dual pressure sensor group to prevent cement particles from accumulating on the probe surface and affecting the measurement accuracy.

[0032] The dual pressure sensors are fixed to the measuring rod with a vertical spacing of Δh = 300mm ± 5mm, located above and below the axis, and connected by a threaded seal. They measure the pressure differential between the two points and use a formula to calculate the slurry density in real time. The sensor probe surface is coated with an alumina ceramic layer (30μm thick, HV1200 hardness) using a micro-arc oxidation process. The corrosion rate in alkaline slurries with a pH of 14 is less than 0.01mm / year.

[0033] The anti-clogging protective cover adopts a conical porous stainless steel filter structure, which covers the surface of the sensor probe. The porous aperture of the anti-clogging protective cover is 0.5mm, and the conical taper is 45°. When installed, it is arranged in a countercurrent layout with the slurry flow direction. Its function is to intercept large particles of impurities and use fluid flushing to achieve self-cleaning to prevent sensor clogging.

[0034] The self-cleaning mechanism is as follows: when the slurry flows through the filter, when the flow rate is 0.8-1.5m / s, local turbulence is formed on the filter surface (Reynolds number Re is greater than 4000), and the tangential stress F || =ρv 2 sinθ (ρ is the slurry density, v is the flow velocity, θ = 45°) is used to peel off the attached particles; at the same time, a reverse pulse airflow (air pressure 0.2 MPa, duration 2 s) is triggered every 10 minutes to completely remove residual impurities.

[0035] The anti-vibration bracket consists of a spring damper and a flange. The spring damping system uses a double helical spring (wire diameter 3mm, outer diameter 25mm, effective number of turns 8) and a hydraulic damper (damping fluid is a silicone-based viscoelastic fluid with a viscosity of 500cP). The damping coefficient c = 1.0N·s / m±0.1, the spring stiffness k = 120N / s±5, and the natural frequency (m = 0.5kg is the mass of the sensor group), effectively suppressing vibration energy from 5Hz to 200Hz, with an attenuation rate exceeding 90%. The bracket body is rigidly connected to the measuring rod via a flange, and the sensor group is suspended within the bracket via a spring damper with a suspension gap of 2mm±0.05, which serves to absorb the impact of the mixing tank vibration pulse and ensure the stability of pressure signal acquisition.

[0036] The LCD display is embedded in the operation panel on the outside of the conveying pipeline, showing the current specific gravity value and historical trend curve in real time, and integrating touch buttons for manual calibration settings.

[0037] Due to the characteristics of cement slurry medium, the present invention adopts a differential pressure densitometer. The calculation principle of the traditional differential pressure densitometer is: in a static liquid, the pressure at a certain point is related to the liquid density and depth, that is, P = P0 + ρgh. For the differential pressure densitometer, the relationship between the pressure difference and density between two points at different depths in the same liquid is mainly used, that is, ΔP = ρgΔh. There are two pressure sensors installed at different heights in the slurry density acquisition device. When working, the two sensors measure the pressures P1 and P2 at their respective locations, and obtain the pressure difference ΔP = P2-P1. Knowing the installation height difference Δh of the two sensors and the gravitational acceleration g, the formula Calculate the liquid density, which is the specific gravity of the cement slurry.

[0038] However, considering the influence of slurry stirring, this patent performs dynamic density correction, and the correction process is as follows.

[0039] In a static slurry, the pressure difference of the dual pressure sensor set is determined only by the static pressure of the slurry:

[0040] ΔP static =ρgΔh

[0041] Among them, Δh = 300 mm is the vertical distance between sensors.

[0042] Stirring causes the slurry to move, generating an additional dynamic pressure difference. Experimental calibration shows that it is related to the stirring blade speed and the slurry viscosity. Through dimensional analysis, the dimensionless correction coefficient k is obtained, which satisfies:

[0043] ΔP dynamic =k·ρ·n 2 ·D 2

[0044] Where k is the device-specific correction factor, n is the impeller speed (rpm), and D is the impeller diameter (m). According to the dynamic density formula, the total pressure difference is the sum of the static pressure difference and the dynamic pressure difference:

[0045] ΔP total =ΔP static +ΔP dynamic

[0046] After substituting, we can get the real-time density:

[0047]

[0048] Through experimental design, the diameter of the agitator paddle is fixed in the calibration tank. By changing the rotation speed, measuring the pressure difference and the true density, and fitting the correction coefficient, it is found that for a cement mixing tank with a slurry tank diameter of 1.5m and an agitator paddle diameter of 0.3m, the correction coefficient k = 0.015 ± 0.002. Other structures cannot be directly applied.

[0049] This formula significantly reduces dynamic errors by correlating the stirring speed with the dynamic pressure difference, and the k value strictly depends on the device structure and tank parameters, making it irreplaceable.

[0050] The following is a comparison of the errors in measuring the specific gravity of cement slurry between this device and the traditional in-tank sensor under various working conditions, as shown in Table 1.

[0051] Table 1 Comparison of specific gravity errors of cement slurry between the present invention and the prior art

[0052]

[0053] (2) Integrated controller

[0054] The integrated controller consists of a 12V regulated power supply and a data controller. The 12V regulated power supply powers the data controller and the slurry density acquisition device. In this embodiment, a Zheyou YHT4L+24 / 20W regulated power supply is used; other brands can also be used, and this embodiment is not limited to this. The data controller receives data such as cement slurry density in real time and transmits it to a wireless data transmission device (DTU) through a port.

[0055] (3) Data Transmitter (DTU)

[0056] The current measurement time and its corresponding slurry specific gravity sent by the integrated controller through the RS-232 interface are wirelessly transmitted to the remote database and application server via the 4G or 5G network. The working process is as follows: First, the data wireless transmission device (DTU) puts the data transmitted by the integrated controller through the RS-232 interface into the FLASH memory, and then sends the data to the CPU (central processing unit) in a "stack" manner through the cache, where the RAM memory is used to temporarily store data. Then, in the data transmission stage, the device connected to the DTU generates data according to the set interval or conditions. The DTU collects the data through the serial port and converts it into a format suitable for wireless network transmission and encapsulates it into a TCP / IP data packet. Then, through the established wireless communication connection, the encapsulated slurry specific gravity data packet is sent to the data center. As the receiving end, the data center will parse and process the received data packets.

[0057] (4) Database and application server

[0058] The database and application server includes a database module, an analysis module, an information feedback module and a communication module.

[0059] The database module primarily consists of two components: receiving and storing data related to slurry density monitoring information. This module interacts with and stores data from the wireless data transmitter (DTU), the remote monitoring terminal for slurry density monitoring, and the analysis module. It first receives and stores data such as the current sampling time and its corresponding slurry density, transmitted by the wireless data transmitter (DTU). In this embodiment of the present invention, an enterprise-level database is used to support data applications. The server is connected to the Internet via optical fiber. Based on the server's designated IP address, the DTU module sends data to the designated IP address and stores the received data in the database.

[0060] The analysis module's primary function is to compare the slurry density measured during the current period with the density control standard input from the remote monitoring system to determine whether the current slurry density meets the control standard. If not, an alarm is sent to the slurry density monitoring device onboard via the 4G or 5G network, prompting construction personnel to make adjustments.

[0061] The information feedback module is used to send alarm information. When the analysis module sends an alarm activation signal, the information feedback module sends an alarm prompt to the on-site slurry specific gravity monitoring machine through the communication module. This information includes the ID number of the measuring device with unqualified specific gravity and the exceeding standard situation. At the same time, the alarm information is sent to the remote monitoring terminal of the slurry specific gravity monitoring through the Internet and recorded for record.

[0062] (5) Slurry specific gravity monitoring airborne terminal equipment

[0063] The onboard device for monitoring slurry density is installed near the control console of the jet grouting machine. Its hardware consists of a color LCD screen, a CPU (Central Processing Unit), FLASH memory, RAM memory, an RS-232 interface, and a power conversion module. The onboard device is powered by an integrated controller (in this case, the supply voltage is 12V), which is transformed by the power conversion module and then supplied to various units, including the CPU, FLASH memory, RAM memory, and color LCD screen.

[0064] The onboard device is connected to the integrated controller via an RS-232 interface, and displays the current measurement time and corresponding slurry density data transmitted by the data controller in real time on an LCD screen. Construction personnel at the slurry station can use this information to promptly adjust operating parameters to achieve pile quality requirements.

[0065] (6) Slurry specific gravity monitoring remote monitoring terminal equipment

[0066] Before monitoring begins, the monitoring client sets control standards for the current slurry density, among other parameters. This data is then stored in the database and application server via the Internet for subsequent use. During monitoring, the client displays the density of each tank of cement slurry in real time, allowing for query and output of monitoring results. Furthermore, it receives alarms from the database and application server indicating substandard slurry density, prompting on-site quality management personnel to make timely adjustments to meet design requirements.

[0067] Although the embodiments and drawings of the present invention are disclosed for illustrative purposes, those skilled in the art will understand that various substitutions, changes and modifications are possible without departing from the spirit and scope of the present invention and the appended claims. Therefore, the scope of the present invention is not limited to the contents disclosed in the embodiments and drawings.

Claims

1. A real-time dynamic monitoring device for cement slurry specific gravity, characterized by: The invention comprises a cement slurry storage tank (1), a slurry specific gravity collection device (2), an integrated controller (3), a data wireless transmission device (4), a database and application server (5), a slurry specific gravity monitoring airborne terminal device (6), and a slurry specific gravity monitoring remote monitoring terminal device (7); the slurry specific gravity collection device (2) is installed on a cement slurry mixing tank or a cement slurry storage tank (1); the slurry specific gravity collection device (2), the integrated controller (3), the data wireless transmission device (4), the database and application server (5), and the slurry specific gravity monitoring remote monitoring terminal device (7) are connected in sequence; and the integrated controller (3) is also connected to the slurry specific gravity monitoring airborne terminal device (6).

2. The real-time dynamic monitoring device for cement slurry specific gravity according to claim 1, characterized in that: The slurry specific gravity acquisition device (2) comprises a dual pressure sensor group (2-1), an anti-clogging protective cover (2-2), an anti-vibration bracket (2-3) and an LCD display (2-4); the dual pressure sensor group (2-1) is fixed to the cement slurry storage tank (1) with a vertical spacing of Δh=300mm±5mm and is threadedly connected to the upper and lower parts of the measuring rod, respectively. The dual pressure sensor group (2-1) calculates the slurry density in real time by measuring the pressure difference between the two points; The anti-clogging protective cover (2-2) is a conical porous stainless steel filter structure, covering the sensor probe surface of the dual pressure sensor group (2-1), the porous aperture of the anti-clogging protective cover (2-2) is 0.5 mm, the conical taper is 45 degrees, and the anti-clogging protective cover (2-2) is arranged in a countercurrent layout with the slurry flow direction when installed, intercepting large particles of impurities and using fluid flushing to achieve self-cleaning, thereby preventing sensor clogging; The anti-vibration bracket (2-3) is composed of a spring damper and a flange. The main body of the anti-vibration bracket (2-3) is rigidly connected to the outer wall via the flange. The dual pressure sensor group (2-1) is suspended inside the anti-vibration bracket (2-3) via the spring damper to absorb the vibration of the stirring tank and the pulse impact of the pipeline, thereby ensuring the stability of pressure signal acquisition. The LCD display (2-4) is embedded in the operation panel outside the conveying pipeline, displays the current specific gravity value and historical trend curve in real time, and integrates touch buttons for manual calibration settings.

3. The real-time dynamic monitoring device for cement slurry specific gravity according to claim 2, characterized in that: The integrated controller (3) includes a 12V regulated power supply and a data controller. The 12V regulated power supply supplies power to the data controller and the slurry specific gravity acquisition device (2). The data controller receives specific gravity data transmitted by the slurry specific gravity acquisition device (2) in real time and transmits the data to the data wireless transmission device (4) through a port.

4. The real-time dynamic monitoring device for cement slurry specific gravity according to claim 3, characterized in that: The data wireless transmission module (4) wirelessly transmits the current measurement time and the corresponding slurry specific gravity sent by the integrated controller to the database and application server (5) via the 4G or 5G network for subsequent use.

5. The real-time dynamic monitoring device for cement slurry specific gravity according to claim 4, characterized in that: The database and application server (5) receive and store the current measurement time and the corresponding slurry specific gravity data information sent from the data wireless transmission module (4), and judge whether the current slurry specific gravity meets the standard according to the slurry density control standard input by the slurry specific gravity monitoring remote monitoring terminal device (7). If not, an alarm is sent to the slurry specific gravity monitoring airborne terminal device (6) through the 4G or 5G network to remind the construction personnel to make adjustments, and the alarm is recorded in the slurry specific gravity monitoring remote monitoring terminal device (7).

6. The real-time dynamic monitoring device for cement slurry specific gravity according to claim 5, characterized in that: The slurry specific gravity monitoring airborne terminal device (6) is installed near the cement slurry mixing tank at the back end of the pulping station, and is connected to the data controller of the integrated controller (3) via a data line. It displays the current measurement time and the corresponding slurry specific gravity transmitted by the data controller in real time. The construction personnel at the back end of the pulping station can adjust the working parameters of the cement slurry to the set requirements in a timely manner based on the displayed information.

7. The real-time dynamic monitoring device for cement slurry specific gravity according to claim 6, characterized in that: The slurry specific gravity monitoring remote monitoring terminal device (7) is installed on a PC or mobile laptop computer that can be connected to the Internet at the construction site. Before monitoring begins, the control standard of the slurry specific gravity is set through the monitoring terminal; then, it is stored in the database and application server (5) through the Internet; during the monitoring process, the client can display the specific gravity of each tank of cement slurry in real time, and can query and output the monitoring results; at the same time, it receives the alarm information sent by the database and application server (5) that the slurry specific gravity does not meet the standard, prompting the on-site quality management personnel to make timely adjustments to meet the design requirements.

Images