An integrated process for precise positioning and centrifugal compaction of steel reinforcement cages for non-prestressed cement poles.

Abstract

This invention relates to the field of building materials and precast concrete component manufacturing technology, and discloses an integrated process for precise positioning and centrifugal compaction of steel reinforcement skeletons for non-prestressed cement poles. It aims to solve the problems of existing centrifugal processes lacking dynamic feedback, failing to effectively correct mid-span deflection of the steel reinforcement skeleton, and being prone to mechanical resonance and uneven pipe wall compaction due to the solidification operation mode. The process uses laser to acquire three-dimensional projection data of the skeleton, driving the support mechanism to apply an upward compensating force for centering and mold closing verification. During the centrifugation stage, the motor current and machine base vibration frequency are monitored to dynamically adjust the speed, phase, and acceleration, achieving adaptive material uniformity and traversing the resonance zone. Simultaneously, the slope of the motor power load change is monitored to determine the compaction degree, and the opening angle of the slurry discharge valve is synchronously adjusted according to the controlled deceleration gradient. This achieves physical centering of the skeleton before mold closing, constructs a dynamic centrifugal closed loop based on dynamic feedback, quantifies the compaction benchmark, and smoothly releases pressure.

Description

Technical Field

[0001] This invention relates to the field of building materials and precast concrete component manufacturing technology, and in particular to an integrated process for precise positioning and centrifugal compaction of steel reinforcement cages for non-prestressed cement poles. Background Technology

[0002] In the current production of non-prestressed cement poles, the most common practice is to use the traditional centrifugal molding process: a pre-tied steel reinforcement frame is placed in a steel mold, and after manual or mechanical placement of the material, the mold is closed and then placed on the rollers of a centrifuge for rotation. This process relies on the centrifugal force generated by the high-speed rotation of the mold to force the concrete slurry to overcome internal friction and spread towards the inner wall of the mold, squeezing out excess water, thereby achieving structural solidification and shaping. This molding method, based on a fixed mechanical trajectory and preset parameters, constitutes the most basic production operation mode in this field.

[0003] However, in actual large-scale component production, this traditional process, lacking dynamic feedback and adaptive adjustment mechanisms, has revealed significant limitations. On the one hand, as the specifications of cement poles increase, the steel reinforcement cage, which can be over ten meters long, is prone to mid-span deflection due to its own weight during mold closing. Traditional rigid mechanical positioning cannot effectively correct this hidden internal physical deformation, easily leading to structural eccentricity or exposed reinforcement defects after the pole is formed. On the other hand, since the concrete slurry poured into the mold inevitably varies in weight, moisture content, and fluidity from batch to batch, the rigid, timed, and constant-speed centrifugation mode used in traditional processes cannot perceive the dynamic distribution of the slurry inside the mold and the stress feedback of the equipment in real time. This blind centrifugation process not only makes it difficult to ensure the uniformity of the pipe wall thickness and the final compaction, but also easily causes severe mechanical resonance or joint leakage when encountering severe eccentric loads, restricting the yield rate and production safety of high-performance, high-standard cement poles. Summary of the Invention

[0004] In view of the aforementioned existing problems, the present invention is proposed.

[0005] Therefore, in order to solve the problems of the lack of dynamic feedback mechanism in the existing traditional centrifugal process, which cannot effectively correct the mid-span downward deflection deformation of the steel reinforcement cage caused by its own weight, and the fact that the fixed centrifugal operation mode cannot adapt to the fluctuation of the concrete slurry state, which easily leads to mechanical resonance, joint leakage and uneven pipe wall density, this invention provides an integrated molding process for precise positioning and centrifugal compaction of steel reinforcement cage for non-prestressed cement poles.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: This invention provides an integrated process for precise positioning and centrifugal compaction of steel reinforcement cages for non-prestressed concrete poles, comprising the following steps: S1. Acquisition of skeleton spatial posture: Before mold closing, the three-dimensional coordinate projection data of the steel skeleton in the mold cavity is acquired by the laser centering sensor, and the three-dimensional coordinate projection data is transmitted to the control center. S2. Dynamic displacement compensation and mold closing: The control center drives the fine-tuning support mechanism to apply an upward compensation force to the steel reinforcement skeleton according to the three-dimensional coordinate projection data, so that the central axis of the steel reinforcement skeleton coincides with the central axis of the mold. After the coincidence, the self-locking clamp is triggered to fix the two ends of the steel reinforcement skeleton and complete the closing of the mold. S3, Adaptive Centrifugal Compaction: The starting motor drives the mold to rotate. The control center monitors the current fluctuation amplitude of the motor and the vibration frequency of the machine base, and dynamically adjusts the speed and acceleration of the motor accordingly, so that the concrete slurry is centrifugally compacted in the mold. S4. Controlled speed reduction and synchronous slurry discharge: The control center determines that the density of the concrete slurry has reached the preset standard based on the load change trend of the motor. Then, it implements controlled braking and deceleration of the motor through the frequency converter, and synchronously adjusts the opening angle of the slurry discharge valve to discharge waste slurry according to the speed reduction gradient.

[0007] As a preferred embodiment of the integrated centrifugal compaction molding process for precise positioning and centrifugal compaction of the reinforcing steel skeleton for non-prestressed cement poles described in this invention, the following steps are taken: Before mold closing, a laser alignment sensor acquires the three-dimensional coordinate projection data of the reinforcing steel skeleton within the mold cavity, and the three-dimensional coordinate projection data is transmitted to the control center. The control system controls the laser alignment sensors located at both ends of the inner wall of the mold to emit laser beams towards the reinforcing steel skeleton and receive the laser beams reflected from the surface of the reinforcing steel skeleton. Based on the time difference between the emission and reception times of the laser beam and the emission angle, the spatial position data corresponding to the reflection point of the reflected laser beam is calculated. The spatial position data is then geometrically stitched together to generate three-dimensional coordinate projection data of the reinforcing steel skeleton within the mold cavity. Initial weight data is obtained using a weighing sensor, and initial slump data is obtained using a slump meter. The control center combines the three-dimensional coordinate projection data, the initial weight data, and the initial slump data to calculate the initial rotational speed command and the expected material homogenization time.

[0008] As a preferred embodiment of the integrated centrifugal compaction molding process for precise positioning and centrifugal compaction of the reinforcing steel skeleton for non-prestressed cement poles described in this invention, the control center drives a fine-tuning support mechanism to apply an upward compensating force to the reinforcing steel skeleton based on the three-dimensional coordinate projection data, so that the central axis of the reinforcing steel skeleton coincides with the central axis of the mold. After coincidence, a self-locking clamp is triggered to fix both ends of the reinforcing steel skeleton and complete the closure of the mold. The specific steps are as follows: The control center extracts the extreme downward deflection at the mid-span of the reinforcing steel skeleton based on the three-dimensional coordinate projection data, and calculates the required upward compensation force deviation value by combining the actual length and diameter of the reinforcing steel skeleton. The control center outputs a thrust command equal in magnitude and opposite in direction to the fine-tuning support mechanism to apply an upward support force to the reinforcing steel skeleton for displacement compensation. If the deviation of the coincidence between the central axis of the reinforcing steel skeleton and the central axis of the mold is less than a preset threshold, the self-locking clamp is triggered to fix both ends of the reinforcing steel skeleton and close the mold. After closing the mold, a mold sealing verification step is also included: the control center uses a visual inspection device to collect images of the joints of the closed mold to identify gaps larger than the safety standard, and pauses subsequent steps when such gaps exist to prevent grout leakage during subsequent centrifugation, which could cause the mold's center of gravity to become unbalanced.

[0009] As a preferred embodiment of the integrated molding process for precise positioning and centrifugal compaction of the reinforcing steel skeleton for non-prestressed cement poles described in this invention, the process involves: starting a motor to drive the mold to rotate; the control center monitoring the current fluctuation amplitude of the motor and the vibration frequency of the machine base, and dynamically adjusting the motor's speed and acceleration accordingly to ensure that the concrete slurry is centrifugally compacted within the mold; the specific steps are as follows: Dynamically adjusting the motor's speed and acceleration includes the low-speed uniform material feeding stage: The control center drives the mold to rotate at a preset initial speed and continuously monitors the current fluctuation amplitude of the motor. When the current fluctuation amplitude shows a periodic peak, it is determined that the uneven distribution of concrete slurry inside the mold causes the center of gravity to deviate. The control center adjusts the output phase of the motor and uses the oscillation of centrifugal torque to induce the concrete slurry to flow into the empty space until the current waveform of the motor returns to smooth.

[0010] Dynamically adjusting the motor's speed and acceleration also includes crossing the resonance zone: After the current waveform of the motor returns to smooth, the control center gradually increases the speed of the motor with a preset fixed acceleration. During the speed increase, the frequency response is collected by the vibration sensor installed on the machine base. If the vibration amplitude of the machine base reaches the set warning line, the control center locks the current speed and performs a fixed-value reverse speed reduction fine adjustment. After the vibration amplitude returns to normal, the acceleration is recalculated to increase the speed, guiding the mold to smoothly cross the critical resonance zone of the equipment.

[0011] The dynamic adjustment of the motor's speed and acceleration also includes a high-speed compaction maintenance phase: After crossing the critical resonance zone, the control center increases the motor speed to the rated maximum speed and monitors the power load change slope of the motor in real time. As the water in the concrete slurry is squeezed out and the structural density increases, the overall rotational inertia of the mold changes. The control center calculates the current density of the concrete slurry by obtaining the degree of slowing down of the power load change slope. If the power load change slope is lower than a preset threshold, it is determined that the density of the concrete slurry has reached the preset standard.

[0012] As a preferred embodiment of the integrated centrifugal compaction molding process for precise positioning and centrifugal compaction of steel reinforcement cages for non-prestressed cement poles described in this invention, the control center determines, based on the load change trend of the motor, that the compaction of the concrete slurry has reached a preset standard. Then, it implements controlled braking and deceleration of the motor via a frequency converter, and synchronously adjusts the opening angle of the slurry discharge valve to discharge waste slurry according to the speed reduction gradient. The specific steps are as follows: During the motor braking deceleration, the control center acquires the gradient data of the current speed decrease and synchronously adjusts the opening angle of the slurry discharge valve according to the gradient data; by matching the deceleration torque and the slurry discharge rate, it prevents the already compacted concrete inner wall from collapsing due to the internal hydraulic impact caused by the sudden drop in the mold speed.

[0013] When applied to cement pole production scenarios in high-corrosion salt spray environments, the control center reduces the braking deceleration rate of the frequency converter during the motor braking deceleration process and controls the slurry discharge valve to open and close in a pulse manner to squeeze the inner wall of the centrifuge and increase the thickness of the dense layer. When applied to cement pole production in high-altitude freeze-thaw environments, the control center triggers high-frequency micro-vibration at the end of the waste slurry discharge process to remove tiny air bubbles remaining on the surface of the centrifuge inner wall.

[0014] The beneficial effects of this invention are: This invention acquires three-dimensional projection data of the steel reinforcement skeleton using a laser alignment sensor, driving a fine-tuning support mechanism to apply an upward compensating force to achieve center axis alignment and mold closing verification. During the centrifugal compaction stage, it monitors motor current fluctuations and machine base vibration frequency, dynamically adjusting speed, output phase, and acceleration to implement adaptive material uniformity and resonance zone crossing. It monitors the slope of motor power load changes to determine compaction, and synchronously couples the opening angle of the slurry discharge valve according to the speed reduction gradient during controlled braking. This achieves physical centering of the steel reinforcement skeleton before mold closing, avoiding structural eccentricity and exposed reinforcement defects. It establishes a dynamic centrifugal speed regulation closed loop based on dynamic feedback, eliminating the risk of local material accumulation and resonance. It quantifies the compaction judgment benchmark and balances deceleration inertia and slurry discharge rate, preventing collapse and spalling of the centrifugal inner wall, ensuring the structural consistency and stability of the formed pole components. Attached Figure Description

[0015] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 Flowchart for obtaining and deriving the S1 skeleton spatial pose; Figure 2 Flowchart for S2 dynamic displacement compensation and mold closing safety verification; Figure 3 Here is the flowchart for the S3 adaptive centrifugal compaction multi-stage control. Figure 4 Customized slurry discharge flowcharts for controlled deceleration and multiple scenarios of S4; Figure 5 This is an adaptive centrifugal speed-time curve. Detailed Implementation

[0017] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0018] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0019] Secondly, the term "one embodiment" or "example" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the invention. The appearance of an embodiment in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that mutually excludes other embodiments.

[0020] Example 1 Reference Figures 1-5 This is the first embodiment of the present invention, which provides an integrated process for precise positioning and centrifugal compaction of the reinforcing steel cage for non-prestressed cement poles, including the following steps: S1. Acquisition of Skeleton Spatial Attitude: Before mold closing, the three-dimensional coordinate projection data of the steel skeleton in the mold cavity is acquired by a laser alignment sensor, and the three-dimensional coordinate projection data is transmitted to the control center. The specific operation steps are as follows: The system controls laser alignment sensors located at both ends of the mold's inner wall to emit laser beams towards the reinforcing steel skeleton and receive the laser beams reflected from the skeleton's surface. Based on the time difference between the emission and reception times of the laser beam and the emission angle, the spatial position data corresponding to the reflection point of the reflected laser beam is calculated. This spatial position data is then geometrically stitched together to generate three-dimensional coordinate projection data of the reinforcing steel skeleton within the mold cavity. Initial weight data is obtained using a weighing sensor, and initial slump data is obtained using a slump meter. The control center combines the three-dimensional coordinate projection data, initial weight data, and initial slump data to calculate the initial rotational speed command and the expected uniform mixing time.

[0021] It should be noted that in the initial preparation stage of precise positioning and centrifugal compaction of the reinforcing steel cage, the system first needs to collect and analyze data on the physical environment and slurry state inside the mold, thereby replacing traditional manual experience-based decision-making with data-driven approaches. The specific operation steps are as follows: Laser scanning ranging and spatial position calculation of reflection points: Before the mold is closed, a high-frequency multi-beam laser alignment sensor, fixedly installed at the reference positioning holes at both ends of the inner wall of the mold, emits an array of laser beams into the steel reinforcement skeleton inside the mold and receives the beams reflected back from the surface of the steel reinforcement skeleton. The timing circuit inside the sensor records the time difference of flight of each laser beam from emission to reception, and, combined with the deflection angle at the time of emission, calculates the specific spatial position data of the reflection point formed by the beam on the surface of the steel reinforcement skeleton. During the process of obtaining the spatial position of the reflection point, the control center obtains the distance based on the time-of-flight ranging principle, and the calculation formula is as follows: Combined with the installation reference point coordinates of the laser alignment sensor ( , , and the horizontal deflection angle of the beam emission and vertical pitch angle , No. The three-dimensional coordinates of each reflection point ( , , The calculation process is as follows: Laser sensor and the surface of the steel reinforcement cage The straight-line distance between each reflection point typically ranges from 0.1m to 2.5m.

[0022] The speed of light constant.

[0023] : No. The time difference between the emission and reception of a laser beam varies depending on the distance, typically ranging from 1 to 20 ns.

[0024] , The real-time deflection angle of the internal galvanometer of the sensor has a range of -45°~45° and -30°~30° respectively.

[0025] Geometric stitching and 3D projection generation of spatial location data: The laser alignment sensor transmits the acquired spatial location data of reflection points to the control center in real time. Upon receiving this scattered point cloud data, the control center maps it onto a coordinate system established with the mold as the reference. A computer program then performs geometric stitching and smooth fitting of the spatial location data to generate complete 3D coordinate projection data of the reinforcing steel skeleton within the mold cavity. This transforms the actual bending or sagging posture of the reinforcing steel skeleton into a 3D digital model that the control system can recognize.

[0026] Material state perception and initial speed command derivation: While acquiring the skeleton posture, weighing sensors distributed on the support nodes of the material placement station measure and report the initial weight data of the concrete slurry poured into the mold in real time. The slump meter obtains the initial slump data of the slurry's consistency through non-contact ranging or image recognition. The control center has a built-in industrial mechanism pre-simulation model, which integrates the three-dimensional coordinate projection data, initial weight data, and initial slump data as core parameters for logical calculations to derive the optimal initial speed command and expected uniformization time required for the subsequent low-speed uniformization stage. This allows for customized control plans to be prepared in advance before centrifugation begins.

[0027] S2. Dynamic Displacement Compensation and Mold Closure: Based on the three-dimensional coordinate projection data, the control center drives the fine-tuning support mechanism to apply an upward compensation force to the steel reinforcement cage, making the central axis of the steel reinforcement cage coincide with the central axis of the mold. After coincidence, the self-locking clamps are triggered to fix both ends of the steel reinforcement cage and complete the mold closure. The specific operation steps are as follows: The control center extracts the extreme downward deflection at the mid-span of the reinforcing steel skeleton based on the three-dimensional coordinate projection data, and calculates the required upward compensation force deviation value by combining the actual length and diameter of the reinforcing steel skeleton. The control center outputs a thrust command equal in magnitude and opposite in direction to the fine-tuning support mechanism to apply an upward support force to the reinforcing steel skeleton for displacement compensation. If the deviation of the coincidence between the central axis of the reinforcing steel skeleton and the central axis of the mold is less than a preset threshold, the self-locking clamp is triggered to fix both ends of the reinforcing steel skeleton and close the mold. After closing the mold, a mold sealing verification step is also included: the control center uses a visual inspection device to collect images of the joints of the closed mold to identify gaps larger than the safety standard, and pauses subsequent steps when gaps are found to prevent grout leakage during subsequent centrifugation, which could cause the mold's center of gravity to become unbalanced.

[0028] It should be noted that during the spatial displacement compensation and mold safety closure stages of the reinforcing steel skeleton, the system needs to dynamically overcome the physical deformation of the skeleton caused by its own weight, and ensure the safe closure of the molding environment after establishing physical constraints. The specific operation steps are as follows: Calculation of Gravity-Induced Deflection and Issuance of Support Commands: Addressing the physical phenomenon of mid-span deflection deformation of the reinforcing steel cage within the mold due to its own weight, the control center extracts the deflection extreme points from the three-dimensional coordinate projection data and, combined with the actual length and diameter of the reinforcing steel cage, calculates the required gravity-induced deflection deviation at the mid-span. To ensure zero deflection at the mid-span (i.e., complete coincidence of the central axis), the control center treats it as an equivalent uniformly loaded beam model with simple supports at both ends, calculating the required upward fine-tuning compensation force. The formula is: : The upward concentrated compensation force required for fine-tuning the support mechanism, in N.

[0029] The uniformly distributed self-weight load per meter of the steel reinforcement cage, in N / m, is determined by the initially obtained cage specification data, and the value range is usually 150N / m~600N / m.

[0030] The effective span between two support points of the steel reinforcement cage within the mold, measured in meters (m), typically ranging from 6m to 18m.

[0031] The control center outputs the deviation value (corresponding to the compensation force) to the fine-tuning support mechanism inside the mold. ) Thrust commands of equal magnitude and opposite direction.

[0032] Dynamic torque balancing and self-locking fastening: After receiving the thrust command, the fine-tuning support mechanism outputs a matching upward support force to smoothly lift the deflected steel reinforcement cage and compensate for displacement. The control center monitors the spatial relationship between the central axis of the steel reinforcement cage and the central axis of the mold in real time. When the deviation of the overlap between these two central axes is reduced to less than the preset threshold, it is determined that the spatial alignment is complete, and the self-locking clamp is triggered to firmly fix both ends of the steel reinforcement cage.

[0033] Visual verification of mold closure and sealing: After the two ends of the reinforcing steel frame are fixed, the actuator completes the mold closure action. Before starting the rotation program, the control center uses a visual inspection device to perform high-frame-rate image acquisition and edge feature extraction on the joint of the closed mold to identify whether there are gaps larger than the safety standard at the joint. If a gap exceeding the standard is identified, the system automatically intercepts subsequent motor start commands and pauses the process to prevent concrete slurry leakage during subsequent centrifugation, thereby avoiding safety accidents caused by mold center of gravity imbalance.

[0034] S3. Adaptive Centrifugal Compaction: The starting motor drives the mold to rotate. The control center monitors the current fluctuation amplitude of the motor and the vibration frequency of the machine base, and dynamically adjusts the motor speed and acceleration accordingly to complete the centrifugal compaction of the concrete slurry within the mold. The specific operation steps are as follows: Dynamically adjusting the motor's speed and acceleration includes the low-speed material feeding stage: The control center drives the mold to rotate at a preset initial speed and continuously monitors the current fluctuation amplitude of the motor. When the current fluctuation amplitude shows a periodic peak, it is determined that the uneven distribution of concrete slurry inside the mold causes the center of gravity to deviate. The control center adjusts the output phase of the motor and uses the oscillation of centrifugal torque to induce the concrete slurry to flow into the empty space until the current waveform of the motor returns to smooth.

[0035] Dynamically adjusting the motor's speed and acceleration also includes navigating the resonance zone: After the motor's current waveform returns to smooth, the control center gradually increases the motor's speed with a preset fixed acceleration. During the speed increase, the frequency response is collected by the vibration sensor installed on the machine base. If the vibration amplitude of the machine base reaches the set warning line, the control center locks the current speed and performs a fixed-value reverse speed reduction fine adjustment. After the vibration amplitude returns to normal, the acceleration is recalculated to increase the speed, guiding the mold to smoothly cross the critical resonance zone of the equipment.

[0036] Dynamically adjusting the motor's speed and acceleration also includes a high-speed compaction maintenance phase: After crossing the critical resonance zone, the control center increases the motor speed to the rated maximum speed and monitors the slope of the motor's power load change in real time. As the water in the concrete slurry is squeezed out and the structural density increases, the overall rotational inertia of the mold changes. The control center calculates the current density of the concrete slurry by obtaining the degree of slowing down of the power load change slope. If the power load change slope is lower than the preset threshold, it is determined that the density of the concrete slurry has reached the preset standard.

[0037] It should be noted that during the adaptive centrifugal compaction stage of the concrete slurry, the system dynamically controls the centrifugation process by capturing the physical response feedback of the drive system and the mechanical structure. The specific operation steps are as follows: Low-speed material distribution and current feedback regulation: The control center issues an initial speed command, and the motor drives the mold to rotate at a preset initial speed while continuously monitoring the stator current fluctuation amplitude of the motor. In the initial stage of low-speed rotation, if the current fluctuation amplitude exhibits periodic peaks, the system determines that uneven distribution of concrete slurry inside the mold has led to eccentric load. The control center adjusts the output phase of the motor by changing the output frequency of the inverter, causing a sudden change in the rotational angular velocity of the mold. This utilizes the oscillation of alternating inertial torque to induce locally accumulated concrete slurry to flow and spread into the empty spaces within the mold until the motor current waveform returns to smooth, confirming balanced material distribution.

[0038] Crossing the Resonance Zone and Vibration Avoidance Speed ​​Adjustment: After the current waveform returns to smooth, the control center gradually increases the motor speed at a preset fixed acceleration. During continuous speed increase, vibration sensors on the machine base continuously collect the frequency response and vibration amplitude of the mechanical structure. When the vibration amplitude of the machine base reaches the set warning line, it indicates that the system is approaching the critical resonance zone. The control center immediately locks the current speed and performs a fixed-value reverse speed reduction fine adjustment to actively avoid the resonance peak. After the system's kinetic energy dissipates and the vibration amplitude falls back to a safe level, the acceleration is recalculated for speed increase, thereby guiding the mold to smoothly cross the critical resonance zone of the equipment.

[0039] High-speed compaction maintenance and load slope calculation: After successfully crossing the critical resonance zone, the control center increases the motor speed to its rated maximum speed and initiates monitoring of the motor power load change slope. With high-speed centrifugal force, free water within the concrete slurry is continuously squeezed out, and solid particles settle, leading to increased structural compaction. The overall rotational inertia of the mold system tends towards a steady state. The control center calculates the first derivative of the motor's active power over time as the power load change slope. The calculation formula is as follows: : The rate of change (slope) of power load within the current time window, in kW / s.

[0040] Current sampling time The active power of the motor is expressed in kW.

[0041] The sampling time window is set, and in order to filter out high-frequency fluctuations in the power grid, the preferred value range is 2s to 5s.

[0042] The control center uses the rate of decrease in the slope of power load change to estimate the current compaction state of the concrete slurry. When certain conditions are met... At that time, (among which) To determine the minimum threshold value for compaction compliance (with a range of 0.05kW / s to 0.15kW / s), the system determines from a kinetic perspective that the compaction of the concrete slurry has reached the preset standard, and automatically terminates the high-speed compaction maintenance stage.

[0043] S4. Controlled Speed ​​Reduction and Synchronous Slurry Discharge: Based on the load change trend of the motor, the control center determines that the density of the concrete slurry has reached the preset standard. Then, it implements controlled motor braking and deceleration via the frequency converter, and synchronously adjusts the opening angle of the slurry discharge valve to discharge waste slurry according to the speed reduction gradient. The specific operation steps are as follows: During motor braking and deceleration, the control center acquires the gradient data of the current speed decrease and adjusts the opening angle of the slurry discharge valve synchronously according to the gradient data; by matching the deceleration torque and the slurry discharge rate, it prevents the already compacted concrete inner wall from collapsing due to the internal hydraulic impact caused by the sudden drop in mold speed.

[0044] When applied to cement pole production scenarios in high-corrosion salt spray environments, the control center reduces the braking deceleration rate of the frequency converter during motor braking and deceleration, and controls the slurry discharge valve to open and close in a pulse manner to squeeze the inner wall of the centrifuge and increase the thickness of the dense layer. When applied to cement pole production in high-altitude freeze-thaw environments, the control center triggers high-frequency micro-vibration at the end of the waste slurry discharge process to remove tiny air bubbles remaining on the surface of the centrifuge inner wall.

[0045] It should be noted that during the controlled deceleration and slurry discharge final stage after centrifugal compaction, the system needs to balance the relationship between deceleration inertia and slurry discharge pressure relief, and perform physical forming reinforcement for different service environments. The specific operation steps are as follows: Gradient braking and slurry discharge pressure relief are synchronized: After determining that the compaction meets the standard, the control center switches to controlled braking mode via the frequency converter to brake and decelerate the motor. During braking and deceleration, the control center continuously acquires the gradient data of the current speed decrease and synchronously and linearly adjusts the opening angle of the slurry discharge valves at both ends of the mold according to the gradient data. The dynamic opening angle of the slurry discharge valves is controlled by the gradient of the mold speed decrease, and its synchronous adjustment calculation formula is as follows: : Slurry discharge valve The real-time opening angle is limited to a range of 0° to 90°.

[0046] The basic opening of the slurry discharge valve is used to ensure the most basic static pressure drainage, and the preferred value range is 5°~15°.

[0047] The discharge coupling coefficient set in the mechanism model is used to quantify the proportional relationship between the deceleration inertial force and the valve flow rate.

[0048] : The gradient of the current angular velocity of the motor (i.e., the absolute value of the deceleration acceleration), in rad / s².

[0049] By matching the deceleration torque with the slurry discharge rate, the discharge velocity of the residual water layer in the mold cavity is ensured to match the decay process of the centripetal acceleration, preventing axial surging and hydraulic impact of the internal water layer due to a sudden drop in mold speed, thereby avoiding peeling or collapse of the already compacted concrete inner wall.

[0050] Pulse extrusion enhancement for high-corrosion salt spray environments: When cement poles are used in production scenarios with high corrosion resistance and salt spray conditions, the control center actively reduces the braking deceleration rate of the frequency converter during motor braking deceleration, extending the mold rotation deceleration time. The control center outputs electrical control pulse signals to the slurry discharge valve, causing it to open and close in a pulsed pattern. The intense fluctuations in water pressure within the mold cavity caused by the valve's opening and closing apply secondary hydraulic extrusion to the inner wall of the concrete, thereby increasing the physical thickness of the dense inner surface layer of the concrete and blocking the penetration channels of external corrosive ions.

[0051] High-frequency micro-vibration venting for high-altitude freeze-thaw environments: When cement poles are used in production scenarios in high-altitude freeze-thaw environments, at the end of the waste slurry discharge process, just before the water film on the inner wall is about to rupture and be completely drained, the control center applies a high-frequency harmonic current to the motor stator, triggering high-frequency micro-vibration. This high-frequency micro-vibration breaks the physical adsorption tension between the residual micro-bubbles on the inner surface of the concrete and the cement slurry, forcing the micro-bubbles remaining on the inner wall of the centrifuge to escape and be discharged with the waste slurry. This reduces the porosity of the inner surface of the cement pole and enhances its structural strength against freeze-thaw cycles.

[0052] Example 2 To further clarify the technical solution of the present invention, the following example, a specific scenario of producing high-performance precast cement poles in an extremely complex geographical and climatic environment, is taken as the second embodiment of the present invention, to provide a more detailed description of the technical solution of the present invention.

[0053] In this embodiment, the production task is to provide special non-prestressed cement poles for a newly built cross-sea high-speed railway line. The production base is located in a coastal area. Because the high-speed railway poles must simultaneously face severe salt spray corrosion (requiring extremely high density) and the extreme cold freeze-thaw cycles of winter (requiring extremely low porosity) during their service life, the requirements for the pole molding quality are extremely stringent. Furthermore, on the day of production, fluctuations in the moisture content of the sand and gravel aggregates caused significant deviations in the initial state of the concrete slurry.

[0054] Step S1: Skeleton Attitude and Extreme Material State Perception At the material placement station before mold closing, a complex 15-meter-long steel reinforcement frame is placed into the lower half of the mold. Due to its own weight and transportation vibrations, the frame undergoes uncontrollable bending inside the mold.

[0055] The system's laser alignment sensor is triggered, and the high-frequency multi-beam lidar scans along the entire length of the frame. The sensor records the time difference of the beam's flight via a timing circuit. Combined with the launch deflection angle , The precise spatial coordinates of tens of thousands of reflection points on the skeleton surface were calculated. , , The control center geometrically stitched and fitted these scattered point cloud data, and constructed a realistic, curved 3D digital model of the spatial posture in the background, identifying the extreme point of mid-span deflection of up to 25mm from the central axis.

[0056] Meanwhile, the weighing sensor at the bottom of the material placement area indicated that the total weight of the slurry far exceeded the standard value (meaning too much material was being placed), and the slump meter visually identified extremely poor slurry flowability (slump of only 10mm, classifying it as semi-dry, stiff concrete). The industrial mechanism simulation model built into the control center aggregated these data on the skeleton's posture, the excessively heavy slurry, and the extremely low slump for logical calculations. The model determined that starting the process according to conventional methods would lead to eccentric vibration and uneven material placement. The system made a proactive decision, reducing the initial centrifugal speed command by 20% and pre-extending the homogenization time by 50%.

[0057] Step S2: Dynamic torque compensation, centering, and mold closing dual verification In response to the identified 25mm mid-span deflection, the control center immediately initiated a dynamic compensation program. The system invoked a simply supported beam load-deformation model, inputting the actual length, diameter, and material density of the frame, to calculate the required upward fine-tuning compensation force. .

[0058] The control center sends a thrust command to the precision servo hydraulic ejector (fine-tuning support mechanism) located at the mid-span of the mold bottom. The ejector output is... An upward supporting force lifts the downward-sloping skeleton segment. The vision inspection system monitors the spatial alignment between the skeleton's central axis and the mold's central axis. When the alignment deviation is detected to be less than the preset 1mm threshold, spatial alignment is determined to be complete, triggering the self-locking clamp action to firmly fix both ends of the skeleton in the absolute center position, and the ejector pin retracts.

[0059] The actuator then completes the mechanical closure of the mold. Before starting rotation, the system automatically enters the sealing verification step. A high-frame-rate industrial camera (visual inspection device) performs a panoramic scan along the 15-meter-long seam line. Using an edge detection algorithm, the system identifies a 0.8mm-wide gap in the middle of the seam line (exceeding the 0.5mm safety threshold, determined to be caused by excessive fabric pressing against the mold). The system immediately intercepts the motor start command and issues a prominent red alarm on the HMI interface, pausing the process. Only after manual intervention to remove foreign objects and the mold is fully closed and sealed, passing the visual verification, is the process allowed to proceed to the next step.

[0060] Step S3: Adaptive Centrifugal Compaction under Complex Dynamic Environments The motor drives the mold to start running via a frequency converter, entering the compaction stage.

[0061] During the low-speed uniform mixing stage: Due to the semi-dry and uneven distribution of the concrete, the mold rotation caused violent vibrations. The control center detected a periodic fluctuation peak of up to 40% in the motor stator current via the current transformer. The system determined that there was a severe eccentric load and immediately issued a torque pulse command, causing a slight abrupt change in the motor's output phase. This artificially induced alternating inertial force oscillation forced the clumps of dry, hardened slurry to overcome mutual resistance and be forcibly spread axially into the empty spaces within the mold. After 30 seconds of continuous oscillation, the current fluctuation amplitude converged to within 5%, the waveform returned to smoothness, and it was confirmed that the slurry had been evenly spread along its entire length.

[0062] During the resonance zone transition phase: The system began to accelerate smoothly. When the speed reached 350 RPM, the piezoelectric vibration sensor on the base suddenly detected that the radial vibration intensity was rapidly approaching the set safety warning line (indicated by the weight of the frame and the amount of slurry, causing a drift in the inherent mechanical frequency of this specific mold specification). The control center immediately locked the current speed to prevent further acceleration, maintaining it for 3 seconds to dissipate inertial energy, and then performed a fixed-value reverse deceleration fine adjustment (rapidly reducing the speed to 320 RPM), actively avoiding the resonance peak point. After the vibration amplitude converged, the system re-planned a gentler acceleration curve for a second sprint, smoothly crossing the new critical resonance zone.

[0063] During the high-speed compaction maintenance phase: the system accelerates to its rated maximum speed (900 RPM). The slope of the motor power load change during system startup is... High-frequency sampling and differentiation. Due to the large mass of the concrete pole, the initial active power is extremely high. As centrifugal propulsion progresses, water is forcefully squeezed out, solid particles settle and compact, the overall rotational inertia of the mold tends to reach a steady state, and the growth rate of the input active power of the drive motor gradually decreases. When the slope of the power load change... The rate of change was continuous for 5 seconds ( Within a time window, the value is lower than the set minimum threshold. At 0.08 kW / s, the control system determines from the dynamics that the internal structural density has reached the standard of high-speed special poles and automatically terminates high-speed maintenance. At this time, the total time of the centrifugal stage is shortened by 15% compared with the conventional process.

[0064] Step S4: Enhance response for the dual special scenarios of salt spray and freeze-thaw cycles. During the deceleration phase, the system learned that this batch of utility poles was clearly marked as requiring both high corrosion resistance (salt spray resistance) and high-altitude freeze-thaw cycles.

[0065] The control center executes variable frequency gradient braking based on the deceleration slope calculated for semi-dry, hard concrete. The control center also dynamically adjusts the opening angle of the electronically controlled proportional slurry discharge valve synchronously based on the current angular velocity descent gradient. .

[0066] To meet the requirements of a high-corrosion-resistance salt spray environment, the system artificially extended the deceleration time and reduced the deceleration gradient in the later stage of the braking phase. At this time, the control center sent a high-frequency pulse signal to the solenoid coil of the slurry discharge valve, causing it to open and close in a pulsed pattern over 30 seconds. This artificially created intense pulse fluctuation of internal water pressure not only completed the slurry discharge but also applied secondary hydraulic pressure to the already compacted cement inner wall, forcing the physical thickness of the innermost dense mortar layer to increase by 2mm, thus enhancing the resistance to chloride ion penetration.

[0067] To meet the requirements of high-altitude freeze-thaw environments, just before the grout discharge process is about to end and the residual water film on the inner wall is about to rupture (at the moment when the free water on the inner wall is about to completely disappear), the control center orders the application of a high-frequency harmonic current superimposed on the fundamental frequency to the motor stator, causing the mold to generate high-frequency micro-amplitude electromagnetic excitation. This high-frequency micro-vibration can break the surface tension between the tiny air bubbles hidden on the inner surface of the concrete and the grout, causing the hidden air bubbles to overflow from the semi-dry surface and be discharged from the mold along with the last remaining waste grout. This significantly reduces the porosity of the inner surface of the cement pole, prevents water from freezing in winter, and enhances the structural strength of the cement pole against freeze-thaw cycle damage.

[0068] When the mold comes to a complete stop, a high-performance special pole for high-speed rail, produced under extreme conditions and meeting the requirements of density and freeze resistance, is formed.

[0069] In summary, this invention acquires three-dimensional projection data of the steel reinforcement skeleton using a laser alignment sensor, driving a fine-tuning support mechanism to apply an upward compensating force to achieve center axis alignment and mold closing verification. During the centrifugal compaction stage, it monitors motor current fluctuations and machine base vibration frequency, dynamically adjusting speed, output phase, and acceleration to implement adaptive material uniformity and resonance zone crossing. It monitors the slope of motor power load changes to determine compaction, and synchronously couples the opening angle of the slurry discharge valve according to the speed reduction gradient during controlled braking. This achieves physical centering of the steel reinforcement skeleton before mold closing, avoiding structural eccentricity and exposed reinforcement defects. It establishes a dynamic centrifugal speed regulation closed loop based on dynamic feedback, eliminating the risk of local material accumulation and resonance. It quantifies the compaction judgment benchmark and balances deceleration inertia and slurry discharge rate, preventing collapse and spalling of the centrifugal inner wall, ensuring the structural consistency and stability of the formed pole components.

[0070] 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 it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A process for precise positioning and centrifugal compaction of steel reinforcement cages for non-prestressed cement poles, characterized in that, Includes the following steps: S1. Acquisition of skeleton spatial posture: Before mold closing, the three-dimensional coordinate projection data of the steel skeleton in the mold cavity is acquired by the laser centering sensor, and the three-dimensional coordinate projection data is transmitted to the control center. S2. Dynamic displacement compensation and mold closing: The control center drives the fine-tuning support mechanism to apply an upward compensation force to the steel reinforcement skeleton according to the three-dimensional coordinate projection data, so that the central axis of the steel reinforcement skeleton coincides with the central axis of the mold. After the coincidence, the self-locking clamp is triggered to fix the two ends of the steel reinforcement skeleton and complete the closing of the mold. S3, Adaptive Centrifugal Compaction: The starting motor drives the mold to rotate. The control center monitors the current fluctuation amplitude of the motor and the vibration frequency of the machine base, and dynamically adjusts the speed and acceleration of the motor accordingly, so that the concrete slurry is centrifugally compacted in the mold. S4. Controlled speed reduction and synchronous slurry discharge: The control center determines that the density of the concrete slurry has reached the preset standard based on the load change trend of the motor. Then, it implements controlled braking and deceleration of the motor through the frequency converter, and synchronously adjusts the opening angle of the slurry discharge valve to discharge waste slurry according to the speed reduction gradient.

2. The integrated molding process for precise positioning and centrifugal compaction of the reinforcing steel cage for non-prestressed cement poles as described in claim 1, characterized in that, The process of obtaining the three-dimensional coordinate projection data of the steel reinforcement skeleton in the mold cavity through the laser alignment sensor in step S1 specifically includes: The laser alignment sensors located at both ends of the inner wall of the mold emit laser beams toward the steel reinforcement skeleton and receive laser beams reflected from the surface of the steel reinforcement skeleton. Based on the time difference between the emission and reception times of the laser beam and the emission angle, the spatial position data of the reflection point corresponding to the reflected laser beam is calculated. The spatial position data is geometrically stitched together to generate three-dimensional coordinate projection data of the steel reinforcement skeleton within the cavity of the mold.

3. The integrated molding process for precise positioning and centrifugal compaction of the reinforcing steel cage for non-prestressed cement poles as described in claim 1, characterized in that... Step S1 further includes collecting initial weight data and initial slump data of the concrete slurry: The initial weight data is obtained using a weighing sensor, and the initial slump data is obtained using a slump detector. The control center combines the three-dimensional coordinate projection data, the initial weight data, and the initial slump data to calculate the initial rotation speed command and the expected uniform material time.

4. The integrated molding process for precise positioning and centrifugal compaction of the reinforcing steel cage for non-prestressed cement poles as described in claim 1, characterized in that, The process of the control center driving the fine-tuning support mechanism to apply an upward compensating force to the steel reinforcement cage in step S2 specifically includes: The control center extracts the extreme downward deflection value at the mid-span of the reinforcing steel skeleton based on the three-dimensional coordinate projection data, and calculates the required upward compensation force deviation value by combining the actual length and actual diameter of the reinforcing steel skeleton; the control center outputs a thrust command equal in magnitude and opposite in direction to the fine-tuning support mechanism to apply an upward support force to the reinforcing steel skeleton for displacement compensation; if the overlap deviation between the central axis of the reinforcing steel skeleton and the central axis of the mold is detected to be less than a preset threshold, the self-locking clamp is triggered to fix both ends of the reinforcing steel skeleton and close the mold.

5. The integrated molding process for precise positioning and centrifugal compaction of the reinforcing steel cage for non-prestressed cement poles as described in claim 4, characterized in that, After closing the mold and before performing step S3, a mold closing seal verification step is also included: The control center uses a visual inspection device to capture images of the seams of the closed mold to identify gaps larger than the safety standard. If such gaps are found, subsequent steps are paused to prevent leakage of slurry during the subsequent centrifugation process, which could cause the mold's center of gravity to become unbalanced.

6. The integrated molding process for precise positioning and centrifugal compaction of the reinforcing steel cage for non-prestressed cement poles as described in claim 1, characterized in that, The dynamic adjustment of the motor's speed and acceleration in step S3 includes a low-speed uniform material feeding stage: The control center drives the mold to rotate at a preset initial speed and continuously monitors the current fluctuation of the motor. When the current fluctuation amplitude shows a periodic peak, it is determined that the uneven distribution of concrete slurry inside the mold has caused the center of gravity to deviate. The control center adjusts the output phase of the motor and uses the oscillation of centrifugal torque to induce the concrete slurry to flow into the empty space until the current waveform of the motor returns to smooth.

7. The integrated molding process for precise positioning and centrifugal compaction of the reinforcing steel cage for non-prestressed cement poles as described in claim 6, characterized in that... The dynamic adjustment of the motor's speed and acceleration in step S3 also includes a stage of crossing the resonance region: After the current waveform of the motor returns to smooth, the control center gradually increases the speed of the motor with a preset fixed acceleration. During the speed increase, the frequency response is collected by the vibration sensor installed on the machine base. If the vibration amplitude of the machine base reaches the set warning line, the control center locks the current speed and performs a fixed-value reverse speed reduction fine adjustment. After the vibration amplitude returns to normal, the acceleration is recalculated to increase the speed, guiding the mold to smoothly cross the critical resonance zone of the equipment.

8. The integrated molding process for precise positioning and centrifugal compaction of the reinforcing steel cage for non-prestressed cement poles as described in claim 7, characterized in that, The dynamic adjustment of the motor's speed and acceleration in step S3 also includes a high-speed compaction maintenance phase: After crossing the critical resonance zone, the control center increases the motor speed to the rated maximum speed and monitors the power load change slope of the motor in real time. As the water in the concrete slurry is squeezed out and the structural density increases, the overall rotational inertia of the mold changes. The control center calculates the current density of the concrete slurry by obtaining the degree of slowing down of the power load change slope. If the power load change slope is lower than a preset threshold, it is determined that the density of the concrete slurry has reached the preset standard.

9. The integrated molding process for precise positioning and centrifugal compaction of steel reinforcement cages for non-prestressed cement poles as described in claim 1, characterized in that, The step S4, which involves synchronously adjusting the opening angle of the discharge valve to discharge waste slurry according to the speed reduction gradient, specifically includes: During the motor braking deceleration, the control center acquires the gradient data of the current speed decrease and synchronously adjusts the opening angle of the slurry discharge valve according to the gradient data; by matching the deceleration torque and the slurry discharge rate, it prevents the already compacted concrete inner wall from collapsing due to the internal hydraulic impact caused by the sudden drop in the mold speed.

10. The integrated molding process for precise positioning and centrifugal compaction of steel reinforcement cages for non-prestressed cement poles as described in claim 9, characterized in that, Step S4 also includes making the following corresponding adjustments based on the production scenario of cement poles: When applied to cement pole production scenarios in high-corrosion salt spray environments, the control center reduces the braking deceleration rate of the frequency converter during the motor braking deceleration process and controls the slurry discharge valve to open and close in a pulse manner to squeeze the inner wall of the centrifuge and increase the thickness of the dense layer. When applied to cement pole production in high-altitude freeze-thaw environments, the control center triggers high-frequency micro-vibration at the end of the waste slurry discharge process to remove tiny air bubbles remaining on the surface of the centrifuge inner wall.

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