A control system for an intelligent pipe pile grouting machine

Abstract

The present invention discloses an intelligent grouting machine control system for pipe piles. The control system comprises a pair of screw grouting machines for grouting large post-tensioned pipe piles; an automatic control device that collects the grouting pressure of the screw grouting machines' grouting channels in real time and continuously and steplessly adjusts the speed of the screw grouting machine's motor based on the grouting pressure to control the grouting speed and flow rate. The present invention automatically adjusts and controls the grouting speed, thereby improving the grouting effect.

Description

Technical Field

[0001] The invention relates to the technical field of grouting machine control. Background Art

[0002] Currently, post-tensioned large pipe piles are widely used in various projects. Their higher bearing capacity and bending resistance can replace some pipe piles, saving project costs. Grouting is a critical step in the post-tensioned prestressing construction process. Grouting quality directly impacts the prestressing effect of large pipe piles, so it requires special attention. Currently, grouting control mostly relies on manual observation, which is prone to errors and reduces the overall grouting quality. Summary of the Invention

[0003] The purpose of the present invention is to provide a pipe pile intelligent grouting machine control system, which automatically adjusts and controls the grouting speed to improve the grouting effect.

[0004] The technical solution to achieve the above purpose is:

[0005] A pipe pile intelligent grouting machine control system, comprising:

[0006] Two screw grouting machines for grouting post-tensioned large tubular piles;

[0007] A control device that collects the grouting pressure of the grouting channel of the screw grouting machine in real time and adjusts the speed of the screw grouting machine according to the grouting pressure control to control the slurry speed and flow rate.

[0008] Preferably, the control device includes a PLC controller, two frequency converters, two analog acquisition modules, two analog output modules, and two pressure sensors;

[0009] Each of the screw grouting machines includes a screw grouting pump and a pressure stabilizing tank connected to the outlet of the screw grouting pump; the pressure stabilizing tank grouts the post-tensioned large pipe piles through the grouting channel;

[0010] The two pressure sensors collect the grouting pressure signals of their respective corresponding grouting channels and transmit them to the analog acquisition module to obtain the corresponding pressure values. The pressure values are subjected to PID calculation by the PLC controller to obtain the PID (proportional, integral, differential) results which are converted into analog values by the analog output module and output to the corresponding frequency converter; the frequency converter adjusts the output frequency;

[0011] The two screw grouting pumps adjust their rotational speeds according to the output frequencies of their respective corresponding frequency converters.

[0012] Preferably, it also includes: two remote controllers,

[0013] The PLC (Programmable Logic Controller) controller receives the control signals of the two remote controllers through a remote control receiver, and controls the output action and frequency of the corresponding frequency converter according to the switch signals converted from the control signals.

[0014] Preferably, it also includes:

[0015] An HMI (human-machine interface) module connected to the control device for human-machine data interaction;

[0016] A host computer connected to the control device and used for inputting grouting control parameters and information, displaying grouting status, drawing and saving a real-time curve of grouting pressure-time process and grouting production reports;

[0017] An information platform that realizes online communication with the host computer.

[0018] Preferably, the HMI module includes a main control page unit and a startup page unit.

[0019] The boot page unit includes a password input box unit for inputting a password and a login switch unit for login control;

[0020] The main control page unit includes:

[0021] Digital input box unit for inputting grouting target pressure and holding time parameters;

[0022] Status display unit for displaying grouting status, variable frequency operation frequency, and real-time pressure value of grouting channel;

[0023] Grouting report unit used to generate and display grouting data reports.

[0024] Preferably, the grouting pressure of the grouting channel collected by the pressure sensor is stabilized at the set pressure, and the timing starts. When the pressure holding time reaches the set pressure holding time, the screw grouting pump stops working, and the PLC controller controls the HMI module to generate a grouting data report, and connects with the information platform in real time through the host computer, so that the tensioning process and report data are uploaded to the information platform in real time.

[0025] Preferably, each of the pressure stabilizing tanks has two slurry outlets for grouting the pipe pile channels through pipelines.

[0026] The beneficial effects of this invention are: It uses pressure sensors to monitor the grouting pressure in each channel in real time, and uses PID calculations to adjust the inverter's output frequency in real time to control the grouting velocity, achieving stable pressure maintenance and improving grouting quality. Furthermore, on-site staff can perform control operations without having to go to the control room, improving on-site response speed. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a structural diagram of the control system of the pipe pile intelligent grouting machine of the present invention. DETAILED DESCRIPTION

[0028] The present invention will be further described below with reference to the accompanying drawings.

[0029] See also Figure 1 The intelligent pipe pile grouting machine control system of the present invention includes: a pair of screw grouting machines, a control device, an HMI module 3, a host computer 4, and an information platform 5.

[0030] The control device collects the grouting pressure of the grouting channel of the screw grouting machine in real time and adjusts the speed of the screw grouting machine according to the grouting pressure control to control the slurry speed and flow rate. The screw grouting machine is used to grout the post-tensioned large pipe pile 100. The HMI module 3 is connected to the control device for human-computer data interaction. The host computer 4 is connected to the control device for inputting grouting control parameters and information, displaying the grouting status, drawing and saving real-time curves of the grouting pressure-time process, and grouting production reports. The information platform 5 realizes online communication with the host computer.

[0031] Specifically, the control device includes a PLC controller 21, two frequency converters 22, two analog acquisition modules 23, two analog output modules (not shown), and two pressure sensors 24. Each screw grouting machine includes a screw grouting pump 11 and a pressure stabilizing tank 12 connected to the outlet of the screw grouting pump 11.

[0032] Among them, the pressure-sustaining tank 12 grouts the post-tensioned large pipe pile 100 through the grouting channel. Each pressure-sustaining tank 12 is separated into two slurry outlets for grouting of the pipe pile channel through pipelines. Two pressure sensors 24 collect the grouting pressure of their respective corresponding grouting channels and transmit it to the analog acquisition module 23 to obtain the corresponding pressure value. The pressure value is PID-operated by the PLC controller 21, and the PID result is converted into an analog output module and output to the corresponding frequency converter 22; the frequency converter 22 adjusts the output frequency; during the process, the slurry is continuously injected into the pipe pile channel through the screw grouting pump 11. When the slurry flows out at the end of the channel, the channel slurry outlet is closed. As the slurry is continuously injected into the channel, the pressure in the grouting channel will slowly increase. The grouting pressure of the grouting channel collected by the pressure sensor 24 is stabilized at the set pressure, and the timing starts. When the pressure holding time reaches the set pressure holding time, the screw grouting pump 11 stops working, and the PLC controller 21 controls the HMI module 3 to generate a grouting data report, and connects with the information platform 5 in real time through the host computer 4, so that the tensioning process and the report data are uploaded to the information platform 5 in real time.

[0033] In addition, two remote controllers 25 are provided, connected to the PLC controller 21. Specifically, the PLC controller 21 receives control signals from the two remote controllers 25 via a remote control receiver and controls the output action and frequency of the corresponding inverter 22 based on the switch signals converted from the control signals. On-site workers can remotely control the grouting equipment, such as starting and stopping, by operating the handheld remote controllers, without having to go to the control room, thus improving on-site response speed.

[0034] In addition, the HMI module 3 includes a main control page unit and a startup page unit. The startup page unit includes a password input box unit for inputting a password and a login switch unit for login control.

[0035] The main control page unit includes:

[0036] Digital input box unit for inputting grouting target pressure and holding time parameters;

[0037] Status display unit for displaying grouting status, variable frequency operation frequency, and real-time pressure value of grouting channel;

[0038] Grouting report unit used to generate and display grouting data reports.

[0039] Human-computer interaction is realized, which facilitates overall control.

[0040] The above embodiments are only used to illustrate the present invention, rather than to limit the present invention. Those skilled in the art may make various changes or modifications without departing from the spirit and scope of the present invention. Therefore, all equivalent technical solutions should also fall within the scope of the present invention and should be defined by the claims.

Claims

1. A pipe pile intelligent grouting machine control system, characterized in that: include: Two screw grouting machines for grouting post-tensioned large pipe piles (100); A control device that collects the grouting pressure of the grouting channel of the screw grouting machine in real time and adjusts the speed of the screw grouting machine according to the grouting pressure to control the slurry speed and flow rate; The control device includes a PLC controller (21), two frequency converters (22), two analog quantity acquisition modules (23), two analog quantity output modules, and two pressure sensors (24); Each of the screw grouting machines comprises a screw grouting pump (11) and a pressure stabilizing tank (12) connected to the outlet of the screw grouting pump (11); the pressure stabilizing tank (12) grouts the post-tensioned large pipe pile (100) through a grouting channel; The two pressure sensors (24) collect grouting pressure signals of their respective corresponding grouting channels and transmit them to the analog quantity acquisition module (23) to obtain corresponding pressure values. The pressure values are subjected to PID calculation by the PLC controller (21). The obtained PID results are converted into analog values by the analog quantity output module and output to the corresponding frequency converter (22); the frequency converter (22) adjusts the output frequency; The two screw grouting pumps (11) adjust their rotational speeds according to the output frequencies of the corresponding frequency converters (22); Also included: two remote controllers (25), The PLC controller (21) receives control signals from the two remote controllers (25) via a remote control receiver, and controls the output action and frequency of the corresponding frequency converter (22) according to the switch signals converted from the control signals; Also includes: An HMI module (3) connected to the control device and used for human-machine data interaction; A host computer (4) connected to the control device and used for inputting grouting control parameters and information, displaying grouting status, drawing and saving a real-time curve of grouting pressure-time process and grouting production reports; An information platform (5) for realizing online communication with the host computer.

2. The intelligent pile grouting machine control system according to claim 1 is characterized in that: The HMI module (3) includes a main control page unit and a startup page unit. The boot page unit includes a password input box unit for inputting a password and a login switch unit for login control; The main control page unit includes: Digital input box unit for inputting grouting target pressure and holding time parameters; Status display unit for displaying grouting status, variable frequency operation frequency, and real-time pressure value of grouting channel; Grouting report unit used to generate and display grouting data reports.

3. The intelligent pipe pile grouting machine control system according to claim 1 is characterized in that: The grouting pressure of the grouting channel collected by the pressure sensor (24) is stabilized at the set pressure, and timing is started. When the pressure reaches the set pressure holding time, the screw grouting pump (11) stops working, and the PLC controller (21) controls the HMI module (3) to generate a grouting data report, and connects with the information platform (5) in real time through the host computer (4), so as to realize the tensioning process and the report data being uploaded to the information platform (5) in real time.

4. The intelligent pile grouting machine control system according to claim 1, characterized in that: Each of the pressure stabilizing tanks (12) is divided into two slurry outlets for grouting the pile channel through pipelines.

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