Intelligent double-liquid grouting system and grouting method

Abstract

The invention discloses an intelligent double-liquid grouting system and a grouting method. The system comprises a liquid A stirring barrel, a liquid B stirring barrel, a double-liquid grouting pump, a slurry mixer, a PID (Proportion Integration Differentiation) regulating valve, a control system, a flow meter, a pressure meter, a flow sensor and a pressure sensor. The liquid A and the liquid B are respectively prepared and then sent out by a double-liquid grouting pump, enter a slurry mixer to be compounded and mixed, and are injected into a target stratum through a directional grouting pipe. The system collects and analyzes flow and pressure data through a control system, and closed-loop regulation and control of grouting flow and proportion are achieved through PID regulation logic. The PID regulating valve has the functions of over-voltage current limiting and overflow prevention at the same time. The method is suitable for reinforcement and leakage treatment under a complex stratum in geotechnical engineering, and has the advantages of being high in matching precision, high in mixing efficiency, good in safety, high in adaptability and the like.

Description

Technical Field

[0001] The present invention relates to the technical field of geotechnical engineering, and in particular to an intelligent double-liquid grouting system and a grouting method. Background Art

[0002] Double-liquid grouting technology is a foundation reinforcement and anti-seepage treatment method widely used in geotechnical engineering. It usually uses two slurries with complementary physical or chemical properties (such as cement-based A liquid and water glass B liquid) to mix on-site and inject into the target formation area. Through its rapid coagulation and expansion reaction in the formation, it can achieve the sealing and reinforcement of unfavorable geological conditions such as broken zones and void areas.

[0003] The existing dual-liquid grouting system usually consists of a grouting bucket, a grouting pump, a mixer and a grouting pipe, but the following problems still exist in actual engineering applications: Low ratio control accuracy: Traditional grouting pumping systems mostly rely on mechanical flow control devices, which cannot achieve dynamic adjustment of the dual-liquid ratio. This is prone to ratio errors, affecting the slurry reaction effect and coagulation strength. Lack of intelligent feedback control mechanism: Most systems control the grouting process based on manual experience and are unable to collect key parameters such as flow rate and pressure in real time. This results in poor grouting stability and difficulty adapting to formation differences. Poor mixing homogeneity: Conventional Y-type or T-type tube mixing devices have simple structures and are difficult to fully mix the slurry, which can easily lead to precipitation, incomplete reaction or tube blockage. Insufficient safety control capabilities: When the grouting pressure rises abnormally or the slurry is blocked, the system lacks an automatic response mechanism, posing safety hazards such as slurry overflow and equipment damage.

[0004] Therefore, there is an urgent need for a dual-liquid grouting system with intelligent feedback regulation, precise proportion control, high mixing efficiency, and a safety protection mechanism to improve grouting quality and construction efficiency. Summary of the Invention

[0005] The purpose of the present invention is to provide an intelligent double-liquid grouting system and grouting method to overcome the problems of inaccurate proportions, poor feedback control capability, poor mixing effect, easy overflow, etc. in the prior art.

[0006] The present invention is implemented by adopting the following technical solutions: an intelligent dual-liquid grouting system, characterized in that it includes a dual-liquid grouting pump for conveying liquid A and liquid B respectively; a liquid A stirring barrel and a liquid B stirring barrel, respectively used to prepare slurries of different components; a slurry mixer for mixing liquid A and liquid B; a control system for intelligently controlling the grouting system; a PID regulating valve, arranged on the dual-liquid grouting pump, for adjusting the output flow of the grouting pump according to the control system instructions; a flow meter and a pressure gauge, respectively arranged on the two outlet pipes of the dual-liquid grouting pump and at the outlet of the slurry mixer, for real-time monitoring of the flow and pressure in each passage; a flow sensor is arranged on the flow meter and electrically connected to the control system; a pressure sensor is arranged on the pressure gauge and electrically connected to the control system; wherein, the control system controls the PID regulating valve to dynamically adjust the output rate and ratio of the dual-liquid grouting pump according to the data fed back by the flow sensor and the pressure sensor, thereby realizing intelligent control of the dual-liquid grouting process.

[0007] Furthermore, the PID regulating valve is also used to trigger a flow limiting or reflux mechanism when the grouting pressure exceeds a set threshold value to prevent slurry from overflowing.

[0008] Furthermore, the slurry mixer includes a Y-type mixing unit and a spiral-impact composite stirring unit. Liquid A and liquid B are first preliminarily collided and mixed in the Y-type mixing unit, and then homogeneously mixed in the spiral-impact mixing unit.

[0009] Furthermore, the control system is constructed based on a PLC control module and is configured with grouting ratio parameters, pressure thresholds, response delays and alarm strategies for automated operation and safety protection.

[0010] Furthermore, the flow meter and pressure gauge are respectively arranged on the A liquid pipeline, the B liquid pipeline and the outlet pipeline of the slurry mixer, forming three groups of detection points, supporting multi-stage status monitoring before, during and after grouting.

[0011] Furthermore, the control system also includes a data acquisition and analysis module, which can optimize subsequent grouting strategies based on historical data of the grouting process and realize self-learning parameter adjustment.

[0012] An intelligent double-liquid grouting method comprises the following steps: Step 1: Set grouting parameters and build a three-dimensional model of the formation to determine the grouting position, depth and pressure range; Step 2: Drilling and cleaning holes to complete the layout and cleaning of grouting holes; Step 3: Assemble the grouting system, connect the components and complete the sensor calibration; Step 4: Prepare liquid A and liquid B and deliver them to the slurry mixer by a dual-liquid grouting pump; Step 5: Based on the data collected by the flow sensor and the pressure sensor, the control system drives the PID control valve to adjust the output of the grouting pump to achieve ratio closed-loop control; Step six, injecting the mixed slurry into the formation through a directional grouting pipe; Step seven: After grouting is completed, it automatically switches to cleaning mode and performs foundation bearing capacity testing after curing.

[0013] The intelligent dual-liquid grouting system and grouting method described in the present invention have the following beneficial effects: The present invention realizes precise control of proportions, improved mixing homogeneity and dynamic adjustment of grouting pressure in the dual-liquid grouting process by constructing a closed-loop control mechanism based on the control system, which significantly improves the intelligence level and construction safety of grouting operations. It realizes data perception of the entire process by setting flow sensors and pressure sensors, and completes automatic flow adjustment and anti-overflow control in combination with PID control valves, effectively overcoming the problems of large proportioning errors, unstable grouting, easy pipe blockage and lack of safety protection in the prior art. It is particularly suitable for directional reinforcement and leakage control projects in complex formation environments, and has the beneficial effects of high proportioning accuracy, fast response speed, good mixing effect and strong construction adaptability. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. The drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the structures shown in these drawings without paying any creative work.

[0015] Figure 1 This is a schematic diagram of an intelligent dual-liquid grouting system; In the figure, 1-dual-liquid grouting pump, 2-A liquid mixing barrel, 3-B liquid mixing barrel, 4-slurry mixer, 5-control system, 6-PID regulating valve, 7-flow meter, 8-pressure gauge, 9-flow sensor, 10-pressure sensor. DETAILED DESCRIPTION

[0016] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0017] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort are intended to fall within the scope of protection of the present invention. Example

[0018] like Figure 1 As shown, an intelligent dual-liquid grouting system mainly includes: a dual-liquid grouting pump 1, a liquid A stirring barrel 2, a liquid B stirring barrel 3, a slurry mixer 4, a control system 5, a PID regulating valve 6, a flow meter 7, a pressure gauge 8, a flow sensor 9 and a pressure sensor 10.

[0019] The A-liquid mixing tank 2 and the B-liquid mixing tank 3 are used to prepare slurries of different components, which are then transported to the dual-liquid grouting pump 1 through corresponding pipelines. The dual-liquid grouting pump 1 adopts a servo drive structure, and its two slurry outlets are connected to the corresponding A / B liquid grouting passages.

[0020] In order to achieve precise and intelligent control of the grouting process, each outlet of the dual-liquid grouting pump 1 is provided with a flow meter 7 and a pressure gauge 8, and a flow sensor 9 is integrated on each flow meter 7, and a pressure sensor 10 is integrated on each pressure gauge 8. These sensors collect the flow and pressure data of the slurry in real time and input the signals into the control system 5.

[0021] The control system 5 is built on a PLC module. Its core function is to intelligently analyze flow and pressure data fed back by sensors and drive the PID control valve 6 through PID control logic, thereby dynamically adjusting the output speed and ratio of the dual-liquid grouting pump 1. This closed-loop control mechanism can maintain the stability of the dual-liquid ratio and the accuracy of the grouting flow rate under construction disturbances such as slurry resistance fluctuations and changes in formation permeability.

[0022] During the mixing process, the two grouting channels converge into a slurry mixer 4. After preliminary mixing via a Y-shaped impactor, the two liquids enter a spiral-impact compound mixer, effectively improving slurry homogeneity and preventing sedimentation or pipe blockage. A flow meter 7 and a pressure gauge 8 are also installed at the outlet of mixer 4 to monitor the final output of the mixed slurry, further enhancing the closed-loop control accuracy of the system.

[0023] Through the design of the above structure and control logic, this system can realize intelligent management and control of the entire process from single-liquid preparation to dynamic injection, and is particularly suitable for foundation reinforcement, leakage control and precision grouting projects under complex geological conditions. Example

[0024] This embodiment provides an intelligent dual-liquid grouting method, which specifically includes the following steps: Step 1: Grouting parameter setting Based on the results of engineering geological surveys, a three-dimensional stratigraphic model is constructed to clearly define the grouting target location, fracture zone orientation, and distribution of underconsolidated areas. Grouting hole locations, depths, injection angles, and expected pressure ranges are determined based on the model. Grouting mix parameters, injection volume control ranges, and construction strategies are pre-set within the control system 5.

[0025] Step 2: Drilling and cleaning Use a drill rig to vertically drill a hole with a diameter of 50–70 mm to a stable layer below the target area (to a depth of no less than the designed depth of 0.6 m). After drilling is complete, high-pressure concentrated mud is injected to clean the hole to remove debris and suspended matter, ensuring a clear slurry channel.

[0026] Step 3: System assembly and debugging Insert the directional grouting pipe with a grout stopper into the bottom of the drilled hole. Connect the A-liquid mixing tank 2 and the B-liquid mixing tank 3, respectively, to supply the corresponding slurry to the two inlets of the dual-liquid grouting pump 1. The slurry outlet is transported to the slurry mixer 4 via a flow meter 7 and a pressure gauge 8. The outlet of the mixer 4 is also equipped with a flow meter 7 and a pressure gauge 8 to monitor the state of the mixed slurry.

[0027] Each flow meter 7 is integrated with a flow sensor 9, and each pressure gauge 8 is integrated with a pressure sensor 10. These sensors are connected to the control system 5. System zero point calibration and threshold setting are completed manually or automatically to ensure accurate system response.

[0028] Step 4: Slurry preparation and synchronous transportation The control system 5 controls the mixing process of Liquid A / B, automatically adding the set component ratio and completing the homogenized mixing through the mixing tank. After filtration, the slurry is delivered by the dual-liquid grouting pump 1. The dual-channel grouting pipeline is equipped with independent flow meters 7 and pressure gauges 8 to monitor the output status of Liquid A and Liquid B in real time.

[0029] Step 5: Intelligent grouting operation Based on data received from flow sensor 9 and pressure sensor 10, control system 5 calculates the current slurry ratio and injection efficiency in real time. If the slurry pressure in a particular channel increases (for example, exceeding a preset threshold of 20%), the system immediately adjusts the flow output of the corresponding channel via PID control valve 6, dynamically adjusting the operating speed of grouting pump 1 to avoid grouting blockage or ratio deviation.

[0030] After intensified mixing in the slurry mixer 4, the mixed slurry is precisely injected into the target formation area through an adjustable directional grouting pipe. The control system further dynamically adjusts the grouting rate and ratio based on the viscosity detector and the formation feedback model.

[0031] Step 6: Grouting completion and automatic cleaning After the single-hole grouting is completed, the control system 5 automatically switches to the cleaning mode, and flushes the grouting pump 1, pipeline and mixer 4 with reverse high-pressure clean water for no less than 10 seconds to prevent the slurry from condensing and clogging the pipe.

[0032] Step 7: Maintenance and effect evaluation After grouting, the holes are sealed and cured for 48 hours. Dynamic penetration or static load tests are used to test the bearing capacity of the reinforced area and assess whether the grouting effect meets the design requirements. The test results are fed back to the system database to provide data support for model corrections in subsequent grouting operations.

[0033] The above embodiments describe the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Without departing from the spirit and scope of the present invention, modifications and variations made by those skilled in the art without departing from the spirit and scope of the present invention should be within the scope of protection of the appended claims.

Claims

1. An intelligent dual-liquid grouting system, characterized in that: The invention comprises a dual-liquid grouting pump (1) for conveying liquid A and liquid B respectively; a liquid A stirring barrel (2) and a liquid B stirring barrel (3) for preparing slurries of different components respectively; a slurry mixer (4) for mixing liquid A and liquid B; a control system (5) for intelligently controlling the grouting system; a PID regulating valve (6) provided on the dual-liquid grouting pump (1) for regulating the output flow of the grouting pump according to the control system instruction; a flow meter (7) and a pressure gauge (8) provided on the two outlet pipes of the dual-liquid grouting pump and the slurry mixer respectively. The outlet of the coupler is used to monitor the flow rate and pressure in each passage in real time; a flow sensor (9) is provided on the flow meter (7) and is electrically connected to the control system (5); a pressure sensor (10) is provided on the pressure gauge (8) and is electrically connected to the control system (5); wherein the control system (5) controls the PID regulating valve (6) to dynamically adjust the output rate and ratio of the dual-liquid grouting pump (1) based on the data fed back by the flow sensor (9) and the pressure sensor (10), thereby realizing intelligent control of the dual-liquid grouting process.

2. An intelligent dual-liquid grouting system according to claim 1, characterized in that: The PID regulating valve (6) is also used to trigger a flow limiting or reflux mechanism when the grouting pressure exceeds a set threshold value to prevent slurry from overflowing.

3. The intelligent dual-liquid grouting system according to claim 1, characterized in that: The slurry mixer (4) comprises a Y-shaped mixing unit and a spiral-impact composite stirring unit. Liquid A and liquid B are initially collided and mixed in the Y-shaped mixing unit, and then homogenized and mixed in the spiral-impact mixing unit.

4. The intelligent dual-liquid grouting system according to claim 1, characterized in that: The control system (5) is constructed based on a PLC control module and is configured with grouting ratio parameters, pressure threshold, response delay and alarm strategy for automated operation and safety protection.

5. The intelligent dual-liquid grouting system according to claim 1, characterized in that: The flow meter (7) and the pressure gauge (8) are respectively arranged on the A liquid pipeline, the B liquid pipeline and the outlet pipeline of the slurry mixer (4), forming three groups of detection points, supporting multi-stage status monitoring before, during and after grouting.

6. The intelligent dual-liquid grouting system according to claim 1, characterized in that: The control system (5) also includes a data acquisition and analysis module, which can optimize subsequent grouting strategies based on historical data of the grouting process and realize self-learning parameter adjustment.

7. An intelligent dual-liquid grouting method, used in the grouting system according to any one of claims 1 to 6, characterized in that: The following steps are involved: Step 1: Set grouting parameters and build a three-dimensional model of the formation to determine the grouting position, depth and pressure range; Step 2: Drilling and cleaning holes to complete the layout and cleaning of grouting holes; Step 3: Assemble the grouting system, connect the components and complete the sensor calibration; Step 4: Prepare liquid A and liquid B and transport them to the slurry mixer (4) through the dual-liquid grouting pump (1); Step 5: The control system (5) drives the PID regulating valve (6) to adjust the output of the grouting pump based on the data collected by the flow sensor (9) and the pressure sensor (10), thereby realizing proportion closed-loop control; Step six, injecting the mixed slurry into the formation through a directional grouting pipe; Step seven: After grouting is completed, it automatically switches to cleaning mode and performs foundation bearing capacity testing after curing.

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