Intelligent pouring device for precast concrete inspection well and machining method of intelligent pouring device

Abstract

The invention discloses an intelligent pouring device for a prefabricated concrete inspection well and a machining method of the intelligent pouring device, and belongs to the technical field of intelligent manufacturing of prefabricated concrete members. The intelligent pouring device comprises a well mold assembly, a collaborative vibrating and supporting part, a pouring executing mechanism and a main controller; the well mold assembly is used for defining a concrete pouring cavity and comprises an inner mold body and an outer mold body which are arranged in a sleeved mode, a distributed temperature measuring array is arranged on the inner wall of the inner mold body, an ultrasonic receiving and transmitting matrix is arranged between the inner mold body and the outer mold body, and a partitioned temperature control unit is arranged on the outer wall of the outer mold body. The collaborative vibrating and supporting part is used for bearing the well mold assembly and applying vibration and comprises a bearing and supporting platform used for placing the well mold assembly, a weighing sensor is arranged on the bearing and supporting platform, a partition type vibrator set is further fixed to the outer wall of an outer mold of the well mold assembly, and the partition type vibrator set is arranged on the bearing and supporting platform. According to the invention, the real-time volume and mass data of the poured concrete are provided for the main controller.

Description

Technical Field

[0001] The present invention relates to the field of intelligent manufacturing of precast concrete components, and in particular to an intelligent pouring device for a precast concrete inspection well and a processing method thereof. Background Art

[0002] In the production of precast concrete inspection wells, the traditional pouring process mainly relies on the workers' on-site experience. This method has significant limitations, namely the inability to perceive and monitor the physical state of the concrete inside the mold, such as density and curing temperature, in real time. Due to the lack of effective process monitoring and data feedback methods, the entire pouring process becomes an open and uncontrollable process, resulting in poor quality uniformity of the finished inspection wells.

[0003] The above-mentioned status quo and shortcomings are mainly due to the limitations of sensing methods and control technologies. Traditional processes are unable to obtain key process parameters inside the casting cavity. When defects such as bubbles and voids appear inside the concrete, managers are unable to detect them in time and take targeted measures. In addition, the global and indiscriminate vibration method cannot accurately apply vibration energy to the areas that really need it, and the hydration heat during the curing process cannot be effectively managed. These factors together lead to potential quality risks in the final product, affecting production efficiency and the qualified rate of finished products.

[0004] The above information disclosed in this Background section is only for enhancement of understanding of the background of the present disclosure and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art. Summary of the Invention

[0005] The purpose of the present invention is to provide an intelligent pouring device for precast concrete inspection wells and a processing method thereof, so as to solve the problems raised in the above-mentioned background technology.

[0006] The technical solution of the present invention is to include a well formwork assembly, a coordinated vibrating and supporting portion, a pouring actuator and a main controller; The well mold assembly is used to enclose a concrete pouring cavity, and includes an inner mold and an outer mold that are nested with each other. A distributed temperature measurement array is provided on the inner wall of the inner mold, an ultrasonic transceiver matrix is ​​provided between the inner and outer molds, and a partitioned temperature control unit is provided on the outer wall of the outer mold; The coordinated vibrating and supporting part is used to carry the well formwork assembly and apply vibration, and includes a load-bearing support platform for placing the well formwork assembly, a weighing sensor is provided on the load-bearing support platform, and a partitioned vibrator group is also fixed on the outer wall of the outer mold of the well formwork assembly; The pouring actuator is used to transport and inject concrete. It spans the well formwork assembly in a gantry structure. The pouring actuator is provided with a raisable pouring hose and a pumping metering unit for measuring the concrete flow rate. The main controller is electrically connected to the distributed temperature measurement array, the ultrasonic transceiver matrix, the partitioned temperature control unit, the weighing sensor, the partitioned vibrator group and the pouring actuator.

[0007] Preferably, the pouring actuator includes a gantry-type moving frame, a lifting pouring hose and a pumping metering unit, the gantry-type moving frame includes a horizontal moving mechanism driven by a servo motor, the lifting pouring hose is suspended on the horizontal moving mechanism and its lifting is controlled by a winch, and the outlet of the pumping metering unit is connected to the lifting pouring hose.

[0008] Preferably, the ultrasonic transceiver matrix includes a first transducer group arranged on the inner wall of the outer mold and a second transducer group arranged on the outer wall of the inner mold. The transducers in the first transducer group and the transducers in the second transducer group are arranged radially opposite to each other along the mold, and together constitute a grid-shaped detection area covering the casting cavity.

[0009] Preferably, the coordinated vibrator and partitioned vibrator group on the support part includes a plurality of variable frequency vibration motors grouped along the annular and height directions of the outer mold; the weighing sensor on the load-bearing support platform is a resistive strain pressure sensor, which is used to measure the total weight of the well mold assembly and the internal concrete in real time.

[0010] An intelligent pouring method for a precast concrete inspection well comprises the following steps: a filling model establishment step, wherein the main controller collects the concrete flow rate provided by the pumping metering unit and the total weight provided by the weighing sensor, and defines the concrete flow rate and total weight data as a pouring process data list; and the main controller establishes a filling state model for characterizing the concrete filling state in the cavity based on the pouring process data list; executing a density diagnosis step, wherein the main controller drives the ultrasonic transceiver matrix to collect ultrasonic signals of the poured area according to the filling state model and defines the signals as a density characterization data set, and identifies defective areas where the density does not meet the standard based on the analysis results of the density characterization data set; Execute the adaptive control step, the main controller drives the partitioned vibrator group corresponding to the defect area to vibrate, and after the vibration is completed, drives the distributed temperature measurement array to collect temperature data to be defined as a curing process temperature data set, and then drives the corresponding partitioned temperature control unit according to the curing process temperature data set to guide the curing process uniformly.

[0011] Preferably, before executing the density diagnosis step, a sensor self-calibration step is also included; The sensor self-calibration step is used to define the moment when the main controller determines that pouring of a certain area is completed as the diagnosis starting time node after the main controller determines that pouring is completed; the main controller first collects static ultrasonic attenuation data once at the diagnosis starting time node, and then instructs the partitioned vibrator group corresponding to the area to apply a preset vibration pulse, and collects dynamic ultrasonic attenuation data once during the vibration; the main controller determines the validity of the data of the corresponding probe in the ultrasonic transceiver matrix by comparing the static and dynamic ultrasonic attenuation data, and uses the valid data or the data estimated by interpolation based on the valid data for subsequent defective area identification.

[0012] Preferably, in the step of establishing the filling model, the main controller also collects the current horizontal position information of the pouring nozzle provided by the gantry-type mobile frame of the pouring actuator, and the height information provided by the lifting pouring hose; the main controller combines the pouring process data list with the position and height information of the pouring nozzle to calculate the theoretical filling height and distribution state of the concrete in the mold cavity in real time in the digital model to establish the filling state model.

[0013] Preferably, in the step of executing adaptive control, the main controller identifies temperature abnormality areas with uneven curing process by calculating the spatial temperature gradient between different measuring points in the curing process temperature data set and the temporal temperature gradient of a single measuring point that changes with time; the main controller instructs the partitioned temperature control unit corresponding to the temperature abnormality area to start micro-cooling or micro-heating function until the spatial temperature gradient and the temporal temperature gradient return to the preset process range.

[0014] The present invention provides an intelligent pouring device for precast concrete inspection wells and a processing method thereof through improvements, which have the following improvements and advantages compared with the prior art: 1. By integrating a distributed temperature measurement array and an ultrasonic transceiver matrix into the well mold assembly, the device can obtain real-time information on the curing temperature and cross-sectional density of the concrete inside the casting cavity. The ultrasonic transceiver matrix, with transducer groups positioned opposite each other on the inner wall of the outer mold and the outer wall of the inner mold, forms a grid-like detection area covering the casting cavity. This allows the specific spatial location of defects such as bubbles and voids to be identified through cross-sectional scanning, providing precise guidance for targeted defect removal. The casting actuator utilizes a gantry structure. The combination of its horizontal movement mechanism and a lifting casting hose enables the casting outlet to move along a preset trajectory in three-dimensional space. This design allows concrete to be gently and layered into designated locations, rather than poured from a single location at high altitude. This effectively reduces the separation of concrete aggregate and mortar, laying the foundation for a uniform and dense concrete structure. Simultaneously, the pumping metering unit works in conjunction with the load cell on the load-bearing support platform to provide the main controller with real-time volume and mass data on the poured concrete. 2. The zoned vibrator group of the coordinated vibration and support part is composed of multiple variable-frequency vibration motors arranged in groups along the annular and height directions of the outer mold; the main controller can independently drive the vibration motor corresponding to the defect area identified by the ultrasonic transceiver matrix for supplementary vibration; this targeted micro-intervention accurately applies vibration energy to the required area, avoiding indiscriminate global vibration of the entire mold, thereby effectively eliminating local defects. The zoned temperature control unit installed on the outer wall of the well mold assembly can actively intervene in the curing process based on the internal temperature data collected by the distributed temperature measurement array; by calculating the spatial temperature gradient between different measuring points and the time-varying temperature gradient of a single measuring point over time, the main controller can identify temperature anomalies in the uneven curing process and drive the corresponding temperature control unit for micro-cooling or micro-heating, thereby ensuring uniform curing of the concrete, reducing the internal stress caused by uneven temperature, and helping to prevent the occurrence of cracks in the later stage; 3. By collecting the flow rate of the pump metering unit, the total weight of the load cell, and the three-dimensional spatial coordinates of the pouring nozzle, a precise filling state model is established that can characterize the concrete filling state within the cavity. This model not only includes the macroscopic total filling volume but also calculates the theoretical filling height and distribution of concrete within the mold in real time, enabling the main controller to accurately judge the pouring progress and providing a basis for timely initiation of subsequent density diagnosis. Before performing the density diagnosis, the method innovatively incorporates a sensor self-calibration step. By comparing static and dynamic ultrasonic attenuation data before and after applying a preset vibration pulse, the main controller can determine the validity of the ultrasonic probe data. This is designed to avoid signal distortion caused by solidified slurry adhering to the probe surface, ensuring the accuracy of the diagnostic results and providing a prerequisite for subsequent precise control. 4. A complete closed-loop process of diagnosis-control-re-diagnosis has been established. After identifying defective areas where the density does not meet the standard, the main controller drives the corresponding vibrator group to vibrate and continuously monitor the area using the ultrasonic transceiver matrix until its density reaches the preset qualified standard. The vibration is stopped only when the density reaches the preset qualified standard. This adaptive control based on real-time data feedback ensures that the casting quality of each local area meets the process requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The present invention will be further explained below in conjunction with the accompanying drawings and Examples: Figure 1 It is a schematic diagram of the overall structure of the device; Figure 2 It is a structural diagram of the pouring actuator; Figure 3 It is a structural diagram of the coordinated vibrating and supporting parts; Figure 4 It is a structural diagram of the well template assembly; Figure 5 It is a schematic flow chart of the method of the present invention; In the figure: 100, well mold assembly; 110, inner mold; 120, outer mold; 130, distributed temperature measurement array; 140, ultrasonic transceiver matrix; 150, partitioned temperature control unit; 200, pouring actuator; 210, gantry mobile frame; 220, lifting pouring hose; 230, pumping metering unit; 300, coordinated vibration and support part; 310, load-bearing support platform; 320, partitioned vibrator group; 400, main controller. DETAILED DESCRIPTION

[0016] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to specific embodiments.

[0017] Example 1 See also Figure 1-4 The present invention provides an intelligent pouring device for a precast concrete inspection well, comprising: a well formwork assembly 100, a coordinated vibrating and supporting portion 300, a pouring actuator 200, and a main controller 400; The well mold assembly 100 is used to enclose a concrete casting cavity and includes an inner mold 110 and an outer mold 120 that are nested together. A distributed temperature measurement array 130 is provided on the inner wall of the inner mold 110, an ultrasonic transceiver matrix 140 is provided between the inner mold 110 and the outer mold 120, and a partitioned temperature control unit 150 is provided on the outer wall of the outer mold 120. The coordinated vibrating and supporting part 300 is used to carry the well formwork assembly 100 and apply vibration. It includes a load-bearing support platform 310 for placing the well formwork assembly 100. The load-bearing support platform 310 is provided with a weighing sensor. A partitioned vibrator group 320 is also fixed to the outer wall of the outer mold 120 of the well formwork assembly 100. The pouring actuator 200 is used to transport and inject concrete. It spans the well formwork assembly 100 in a gantry-type structure. The pouring actuator 200 is equipped with a raisable pouring hose and a pumping metering unit 230 for measuring the concrete flow rate. The main controller 400 is electrically connected to the distributed temperature measurement array 130 , the ultrasonic transceiver matrix 140 , the partitioned temperature control unit 150 , the weighing sensor, the partitioned vibrator group 320 and the pouring actuator 200 .

[0018] This embodiment provides an intelligent pouring device for precast concrete inspection wells, which aims to solve the problems in the prior art that the concrete pouring process relies on manual experience, cannot perceive the internal quality status in real time, and has poor uniformity of the finished product; the intelligent pouring device uses the multi-dimensional sensor integrated in the well mold assembly 100, combined with the precise operation of the coordinated vibration and support part 300 and the pouring actuator 200, and is uniformly dispatched by the main controller 400; wherein, the well mold assembly 100 serves as the molding basis, and the built-in distributed temperature measurement array 130 and ultrasonic transceiver matrix 140 provide a physical basis for obtaining the internal curing temperature and density information of the concrete; collaborative The weighing sensor and the partitioned vibrator group 320 on the vibrating and supporting part 300 are used to obtain the macro data of the total amount of pouring and the micro intervention of applying local vibration respectively; the pouring actuator 200 controls the amount and position of concrete injection through its pumping metering unit 230 and movable pouring hose; the main controller 400, such as the Siemens S7-1200 series PLC, links these sensing and execution components, transforming the pouring process from an open, uncontrollable process to a data-driven, controllable manufacturing process, providing the possibility of improving the overall quality and production efficiency of prefabricated inspection wells.

[0019] The pouring actuator 200 includes a gantry-type moving frame 210, a lifting pouring hose 220 and a pumping metering unit 230. The gantry-type moving frame 210 includes a horizontal moving mechanism driven by a servo motor. The lifting pouring hose 220 is suspended on the horizontal moving mechanism and its lifting is controlled by a winch. The outlet of the pumping metering unit 230 is connected to the lifting pouring hose 220.

[0020] The pouring actuator 200 in this embodiment is designed to achieve precise distribution of concrete within the pouring cavity. The pouring actuator 200, through the design of the gantry-type movable frame 210, has a working range that can completely cover the well mold assembly 100 below. The horizontal movement mechanism on the gantry-type movable frame 210 can be specifically composed of a ball screw pair and driven by a servo motor. This configuration allows the lifting pouring hose 220 suspended thereon to be accurately positioned on the horizontal plane. At the same time, the lifting pouring hose 220 is controlled by a winch, such as a wire rope drum driven by a brake motor with a self-locking function. In this way, the discharge port of the pouring hose can move along a preset trajectory in three-dimensional space. Its function is to gently and layer concrete at a specified location according to the pouring process, rather than pouring it from a single high location. This helps to reduce the separation of concrete aggregate and mortar, laying the foundation for the subsequent acquisition of a uniform and dense concrete structure.

[0021] The ultrasonic transceiver matrix 140 includes a first transducer group arranged on the inner wall of the outer mold 120 and a second transducer group arranged on the outer wall of the inner mold 110. The transducers in the first transducer group and the transducers in the second transducer group are arranged opposite to each other along the radial direction of the mold, together forming a grid-shaped detection area covering the casting cavity.

[0022] The ultrasonic transceiver matrix 140 in this embodiment is designed to obtain cross-sectional density information of the concrete within the casting cavity. The first and second transducer groups of the ultrasonic transceiver matrix 140 are mounted on the outer mold 120 and inner mold 110, respectively, and are arranged in a one-to-one correspondence along the radial direction of the mold, i.e., the thickness direction. This layout allows each pair of transducers to form an independent ultrasonic detection path. When all the detection paths are combined, a grid-like detection area is formed within the annular space of the casting cavity. This allows for cross-sectional scanning of the concrete's internal conditions, rather than single-point or single-line measurements. When defects such as bubbles or voids are present in the concrete, the ultrasonic signal attenuation in this area is significantly increased. By analyzing the signal attenuation data of each path within this grid, the main controller 400 can identify the specific spatial location of the defect, providing accurate guidance for subsequent targeted defect removal.

[0023] The partitioned vibrator group 320 on the coordinated vibration and support part 300 includes a plurality of variable frequency vibration motors grouped along the annular and height directions of the outer mold 120; the weighing sensor on the load-bearing support platform 310 is a resistive strain pressure sensor, which is used to measure the total weight of the well mold assembly 100 and the internal concrete in real time.

[0024] The coordinated vibration and support part 300 in this embodiment is intended to provide precise vibration energy and monitor the total amount of material in real time; the partitioned vibrator group 320 is composed of a plurality of variable frequency vibration motors, which are divided into several independent areas along the circumference and height direction of the outer mold 120; the use of variable frequency vibration motors is used in that the main controller 400 can independently adjust the vibration frequency and start and stop of each motor, which means that the vibration energy can be accurately applied to the required area, rather than indiscriminate global vibration of the entire mold; the weighing sensor on the load-bearing support platform 310 can specifically use a plurality of sets of parallel resistance strain type pressure sensors, which is used to measure the total weight of the well mold assembly 100 together with the internal concrete in real time and continuously; after subtracting the known empty weight of the mold from this total weight data, the real-time mass of the poured concrete can be obtained, which provides basic data for the main controller 400 to establish a filling model.

[0025] Example 2 See also Figure 5 , an intelligent pouring processing method for precast concrete inspection wells, comprising the following steps: In the step of establishing a filling model, the main controller 400 collects the concrete flow rate provided by the pumping metering unit 230 and the total weight provided by the weighing sensor, and defines the concrete flow rate and total weight data as a pouring process data list. The main controller 400 establishes a filling state model for representing the concrete filling state in the cavity based on the pouring process data list; In the density diagnosis step, the main controller 400 drives the ultrasonic transceiver matrix 140 to collect ultrasonic signals from the poured area according to the filling state model and defines them as a density characterization data set. Based on the analysis results of the density characterization data set, defective areas with substandard density are identified. Execute the adaptive control step, the main controller 400 drives the partitioned vibrator group 320 corresponding to the defect area to vibrate, and after the vibration is completed, drives the distributed temperature measurement array 130 to collect temperature data to be defined as the curing process temperature data set, and then drives the corresponding partitioned temperature control unit 150 according to the curing process temperature data set to guide the uniformity of the curing process.

[0026] The present embodiment provides a method for processing a precast concrete inspection well, the purpose of which is to transform the pouring process into a perceptible and controllable process; a filling model step is established, the purpose of which is to allow the main controller 400 to understand the filling status of the concrete in the mold in real time; the main controller 400 obtains the volume of injected concrete through a pumping metering unit 230, such as an electromagnetic flowmeter, and obtains the injected mass through a weighing sensor, and these two data constitute a pouring process data list; based on this list, the main controller 400 can calculate the real-time density of the current batch of concrete and establish a filling state model that describes the filling state of the concrete in the cavity. The density diagnosis step is executed, the purpose of which is to actively check whether there are defects inside the concrete after pouring is completed; when the filling state model shows that a certain area has been poured, the main controller 400 drives the ultrasonic transceiver matrix 140 to scan the area, and the obtained ultrasonic signal is defined as a density characterization data set; by analyzing the attenuation degree of the signal in the data set, defective areas caused by insufficient vibration can be identified; The identification here is based on a preset density qualification standard, which is a quantified judgment threshold based on the attenuation characteristics of ultrasonic waves when propagating in concrete. The value is pre-calibrated and stored in the main controller 400 based on ultrasonic testing experiments on standard concrete test blocks with known good density, or based on the ultrasonic signal characteristics of high-quality finished products in historical production data. During the diagnosis process, the main controller 400 compares the real-time ultrasonic attenuation value with the preset threshold point by point. When the attenuation value of a certain area exceeds the threshold, it is determined to be a defective area with substandard density. This serves as a logic trigger signal, driving the main controller 400 to perform subsequent targeted supplemental vibration on the area. The adaptive control step is executed to eliminate defects and guide the curing process in a targeted manner. Based on the results of the density diagnosis, the main controller 400 drives the partitioned vibrator group 320 corresponding to the defective area for supplemental vibration. During the supplemental vibration process, the main controller 400 drives the ultrasonic transceiver matrix 140 to scan the area again and compares the newly acquired density characterization data with the preset qualified standard. Vibration of the area is not stopped until the density of the area meets the qualified standard. After confirming that the density of all areas is qualified and the vibration is completed, in order to manage the hydration heat of concrete, the main controller 400 turns to using the distributed temperature measurement array 130 to collect temperature data, forming a curing process temperature dataset. Based on this dataset, the main controller drives the corresponding partitioned temperature control unit 150 for fine-tuning to achieve uniform guidance of the curing process. The purpose is to reduce the internal stress caused by temperature unevenness, thereby improving the durability of the finished product.

[0027] Before executing the density diagnosis step, a sensor self-calibration step is also included; The sensor self-calibration step is used to define the moment when the main controller 400 determines that pouring of a certain area is completed as the diagnosis starting time node after the main controller 400 determines that pouring is completed; the main controller 400 first collects static ultrasonic attenuation data once at the diagnosis starting time node, and then instructs the partitioned vibrator group 320 corresponding to the area to apply a preset vibration pulse, and collects dynamic ultrasonic attenuation data once during the vibration; the main controller 400 determines the validity of the data of the corresponding probe in the ultrasonic transceiver matrix 140 by comparing the static and dynamic ultrasonic attenuation data, and uses the valid data or the data estimated by interpolation based on the valid data for subsequent defective area identification.

[0028] The sensor self-calibration step in this embodiment is intended to ensure that the data source used for density diagnosis is reliable. In a concrete environment, slurry may adhere to the surface of the ultrasonic probe and solidify, causing signal distortion. Therefore, before executing the density diagnosis step, the main controller 400 will first perform a data validity query. The process is as follows: at the diagnosis start time node, the main controller 400 first records static ultrasonic attenuation data when vibration stops. Then, it instructs the vibrator in the area to apply a short vibration pulse and records dynamic ultrasonic attenuation data while vibrating. The judgment logic is that if the probe is working properly, the internal structure of the flowing concrete will undergo slight changes under the action of vibration, resulting in a significant difference between the dynamic data and the static data. Conversely, if the probe is covered by solidified slurry, the vibration will not affect the signal it receives, and the two data will be very close. By comparing the difference between the two data, the main controller 400 can determine the validity of the probe data, thereby avoiding erroneous defect judgments due to invalid data, thereby ensuring the accuracy of subsequent adaptive control.

[0029] During the filling model establishment step, the main controller 400 also collects the current horizontal position information of the pouring nozzle provided by the gantry movable frame 210 of the pouring actuator 200, and the height information provided by the lifting pouring hose 220; the main controller 400 combines the pouring process data list with the position and height information of the pouring nozzle to calculate the theoretical filling height and distribution state of concrete in the mold cavity in real time in the digital model to establish the filling state model.

[0030] The calculation process is as follows: a three-dimensional digital twin model that is completely consistent with the actual casting cavity is pre-built within the main controller 400. The model is divided into fine grid units, or voxels. After casting begins, the controller accumulates the concrete volume measured by the pumping metering unit 230 during the corresponding time interval to the voxel directly below it based on the real-time three-dimensional coordinates of the casting hose nozzle. At the same time, the model has a built-in simplified algorithm based on a preset angle of repose or viscosity coefficient to simulate the natural flow and flattening process of newly injected concrete toward adjacent voxels under the action of gravity, thereby dynamically generating a theoretical concrete distribution surface. To ensure model accuracy, the main controller 400 also obtains the theoretical total mass by multiplying the real-time accumulated total injection volume by the concrete density. This theoretical total mass is continuously compared with the actual total mass measured by the weighing sensor, and the difference is used to calibrate the model to form a high-precision real-time filling state model. This embodiment refines the steps for establishing the filling model to construct a more accurate filling state model. A pouring process data list containing only total weight and total volume can only provide a macroscopic filling amount but cannot describe the distribution of concrete within the mold. Therefore, while collecting weight and volume data, the main controller 400 also obtains the real-time three-dimensional spatial coordinates of the pouring nozzle from the pouring actuator 200, namely, horizontal position information provided by the gantry-type movable frame 210 and height information provided by the lifting pouring hose 220. The main controller 400 combines this position information with the pouring process data list and, through calculation, can depict the theoretical filling height and surface distribution of concrete within the mold cavity in real time in the digital model. The effect of this more detailed filling state model is that the main controller 400 can more accurately determine when and where pouring is completed, thereby enabling more timely and accurate initiation of subsequent density diagnosis, thereby improving the collaborative efficiency of the entire processing method.

[0031] During the adaptive control step, the main controller 400 identifies abnormal temperature areas with uneven curing process by calculating the spatial temperature gradient between different measuring points in the curing process temperature data set and the temporal temperature gradient of a single measuring point over time; the main controller 400 instructs the partitioned temperature control unit 150 corresponding to the abnormal temperature area to start the micro-cooling or micro-heating function until the spatial temperature gradient and the temporal temperature gradient return to the preset process range.

[0032] This embodiment refines the curing guidance process in the adaptive control step, with the aim of achieving precise management of the concrete hydration thermal reaction process. Concrete releases heat during curing, and uneven heat dissipation will cause internal temperature stress. The main controller 400 calculates two key indicators by analyzing the curing process temperature data set: one is the temperature difference between different measuring points, namely the spatial temperature gradient; the other is the rate of change of the temperature of a single measuring point over time, namely the time temperature gradient. A large spatial temperature gradient indicates that a certain location is overheated or too cold, while a large time temperature gradient indicates that a certain location is too violent in its hydration reaction. Through these two gradient values, the main controller 400 can accurately identify abnormal temperature areas with uneven curing processes. The preset process range used for identification and control here refers to the allowable fluctuation range of the spatial temperature gradient and temporal temperature gradient during the concrete curing process, pre-set by the main controller 400. This range is intended to control the internal and external temperature difference and cooling rate caused by hydration heat to a safe level that does not generate harmful thermal stress. The upper and lower limits are determined through thermodynamic simulation calculations and experimental verification after comprehensive consideration of the concrete mix ratio, manhole wall thickness, cement thermophysical properties, and relevant industry specifications. Once any gradient value calculated by the main controller 400 exceeds this range, the corresponding zoned temperature control unit 150 is triggered to activate the micro-cooling or micro-heating function until the temperature gradient in the area returns to within the preset process range. The main controller 400 instructs the zoned temperature control unit 150 corresponding to the abnormal area, such as a Peltier semiconductor refrigeration and heating module, to perform targeted micro-cooling or micro-heating; the function is to actively intervene in local heat in this way, maintain the spatial and temporal temperature gradients within a smaller preset process range, ensure the overall uniform curing of the concrete, help prevent the occurrence of later cracks, and thus ensure the long-term structural stability of the final product.

[0033] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. An intelligent pouring device for precast concrete inspection wells, characterized by: include: Well formwork assembly (100), coordinated vibrating and supporting portion (300), pouring actuator (200) and main controller (400); The well mold assembly (100) is used to enclose a concrete casting cavity, and comprises an inner mold (110) and an outer mold (120) that are sleeved together. A distributed temperature measurement array (130) is provided on the inner wall of the inner mold (110), an ultrasonic transceiver matrix (140) is provided between the inner mold (110) and the outer mold (120), and a partitioned temperature control unit (150) is provided on the outer wall of the outer mold (120); The coordinated vibrating and supporting portion (300) is used to carry the well formwork assembly (100) and apply vibration, and comprises a load-bearing support platform (310) for placing the well formwork assembly (100), a weighing sensor being provided on the load-bearing support platform (310), and a partitioned vibrator group (320) being fixed on the outer wall of the outer mold (120) of the well formwork assembly (100); The pouring actuator (200) is used to transport and inject concrete, and is arranged across the well formwork assembly (100) in a gantry-type structure. The pouring actuator (200) is provided with a pouring hose that can be raised and lowered, and a pumping metering unit (230) for measuring the flow rate of concrete. The main controller (400) is electrically connected to the distributed temperature measurement array (130), the ultrasonic transceiver matrix (140), the partitioned temperature control unit (150), the weighing sensor, the partitioned vibrator group (320), and the pouring actuator (200).

2. The intelligent pouring device for precast concrete inspection well according to claim 1, characterized in that: The pouring actuator (200) comprises a gantry-type moving frame (210), a lifting pouring hose (220) and a pumping metering unit (230); the gantry-type moving frame (210) comprises a horizontal moving mechanism driven by a servo motor; the lifting pouring hose is suspended on the horizontal moving mechanism and its lifting is controlled by a winch; and the outlet of the pumping metering unit (230) is communicated with the lifting pouring hose (220).

3. The intelligent pouring device for precast concrete inspection well according to claim 1, characterized in that: The ultrasonic transceiver matrix (140) comprises a first transducer group arranged on the inner wall of the outer mold (120) and a second transducer group arranged on the outer wall of the inner mold (110), wherein the transducers in the first transducer group and the transducers in the second transducer group are arranged opposite to each other along the radial direction of the mold, and together form a grid-shaped detection area covering the casting cavity.

4. The intelligent pouring device for precast concrete inspection well according to claim 1, characterized in that: The partitioned vibrator group (320) on the coordinated vibrating and supporting part (300) includes a plurality of variable frequency vibration motors arranged in groups along the annular and height directions of the outer mold (120); the weighing sensor on the load-bearing support platform (310) is a resistance strain type pressure sensor, which is used to measure the total weight of the well mold assembly (100) and the concrete inside in real time.

5. An intelligent casting method for precast concrete inspection wells, applied to the device according to any one of claims 1 to 4, characterized in that: The steps include: In a filling model establishment step, the main controller (400) collects the concrete flow rate provided by the pumping metering unit (230) and the total weight provided by the weighing sensor, and defines the concrete flow rate and total weight data as a pouring process data list. The main controller (400) establishes a filling state model for characterizing the concrete filling state in the cavity based on the pouring process data list; Executing a density diagnosis step, the main controller (400) drives the ultrasonic transceiver matrix (140) to collect ultrasonic signals of the poured area according to the filling state model and defines the signals as a density characterization data set, and identifies defective areas where the density does not meet the standard based on analysis results of the density characterization data set; The adaptive control step is performed, wherein the main controller (400) drives the partitioned vibrator group (320) corresponding to the defective area to vibrate, and after the vibration is completed, drives the distributed temperature measurement array (130) to collect temperature data to be defined as a curing process temperature data set, and then drives the corresponding partitioned temperature control unit (150) according to the curing process temperature data set to guide the uniformity of the curing process.

6. The intelligent pouring method for precast concrete inspection well according to claim 5, characterized in that: Before executing the density diagnosis step, a sensor self-calibration step is also included; The sensor self-calibration step is used to define the moment when the main controller (400) determines that pouring of a certain area is completed as a diagnosis start time node after the main controller (400) determines that pouring is completed; the main controller (400) first collects static ultrasonic attenuation data once at the diagnosis start time node, and then instructs the partitioned vibrator group (320) corresponding to the area to apply a preset vibration pulse, and collects dynamic ultrasonic attenuation data once during the vibration; the main controller (400) determines the validity of the data of the corresponding probe in the ultrasonic transceiver matrix (140) by comparing the static and dynamic ultrasonic attenuation data, and uses the valid data or the data estimated by interpolation based on the valid data for subsequent defective area identification.

7. The intelligent pouring method for precast concrete inspection well according to claim 5, characterized in that: In the step of establishing the filling model, the main controller (400) further collects the current horizontal position information of the pouring nozzle provided by the gantry-type movable frame (210) of the pouring actuator (200), and the height information provided by the lifting pouring hose (220); the main controller (400) combines the pouring process data list with the position and height information of the pouring nozzle to calculate the theoretical filling height and distribution state of the concrete in the mold cavity in real time in the digital model to establish the filling state model.

8. The intelligent pouring method for precast concrete inspection well according to claim 5, characterized in that: In the step of executing the adaptive control, the main controller (400) identifies the temperature abnormality area of ​​the uneven curing process by calculating the spatial temperature gradient between different measuring points in the curing process temperature data set and the time temperature gradient of a single measuring point changing with time; the main controller (400) instructs the partitioned temperature control unit (150) corresponding to the temperature abnormality area to start the micro-cooling or micro-heating function until the spatial temperature gradient and the time temperature gradient return to the preset process range.

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