A method and system for monitoring the internal concrete condition of a mixer
By monitoring the temperature, humidity, and density data of concrete inside the mixer, calculating the moisture content, and combining video monitoring and pressure sensors, the problem of real-time monitoring during concrete production has been solved, achieving efficient quality control and early warning, and improving production stability and construction progress.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- SHENZHEN HUIJI CONCRETE CO LTD
- Filing Date
- 2023-07-04
- Publication Date
- 2026-06-02
AI Technical Summary
The current concrete production process cannot achieve real-time monitoring, resulting in unstable production quality, affecting construction progress and building quality, and the manual judgment method is not accurate enough.
The monitoring unit acquires temperature, humidity, and density data of the concrete, the processing unit calculates the moisture content and determines the quality status, and video monitoring and pressure sensors detect blockages in the feed pipe to achieve real-time monitoring and early warning.
It enables real-time monitoring of the concrete state inside the mixer, providing timely warnings in case of abnormalities, improving the stability and efficiency of production quality, and reducing the uncertainty of human intervention.
Smart Images
Figure CN116811007B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of concrete production technology, and in particular to a method and system for monitoring the state of concrete inside a mixer. Background Technology
[0002] Currently, in the traditional building materials production industry, especially in the concrete production sector, the quality control of raw materials and the production process are still dominated by a large number of inefficient, non-standard, and extensive production management methods. This has led to a series of economic and social problems, such as a huge waste of raw materials, ineffective investment in production costs, extremely unstable product quality, and increasingly prominent environmental issues.
[0003] For testing the rheological properties of concrete, in the current concrete production process, experienced engineers typically take samples of the mixed concrete after discharge and then test its slump. It is worth noting that batching plants across the country frequently encounter problems such as discarding materials and remixing due to substandard workability of the concrete after mixing. These issues seriously affect construction progress and even jeopardize building quality. Secondly, the development of the building materials industry has placed higher demands on concrete production. In most cases, construction projects have very tight schedules, making it difficult to adapt to the method of manually judging concrete workability. Furthermore, the manual experience method itself introduces unstable factors, which is very detrimental to the precise control of concrete quality.
[0004] Concrete production quality is a crucial aspect of construction and requires real-time monitoring to effectively ensure its quality. Therefore, there is an urgent need for a method and system for monitoring the state of concrete inside a mixer to address these issues. Summary of the Invention
[0005] To address the issue of the inability to monitor concrete conditions in real time during concrete production, this application provides a method for monitoring the state of concrete inside a mixer.
[0006] In a first aspect, this application provides a method for monitoring the state of concrete inside a mixer, comprising:
[0007] The first monitoring data of the concrete is obtained through the monitoring unit. The first monitoring data includes the temperature monitoring data, humidity monitoring data and density monitoring data of the concrete.
[0008] The processing unit processes the temperature detection data, humidity detection data, and density detection data to generate the quality status of the concrete.
[0009] When the concrete is in an abnormal quality state, the second monitoring data of the concrete is acquired, and a first early warning message is sent to the receiving terminal. The second monitoring data includes video monitoring data of the concrete.
[0010] Optionally, the step of processing the temperature detection data, humidity detection data, and density detection data through the processing unit to generate the quality status of the concrete includes:
[0011] The temperature detection data, humidity detection data, and density detection data are processed by the processing unit to obtain the first moisture content of the concrete;
[0012] The first moisture content is compared with a first threshold and a second threshold to determine the quality status of the concrete.
[0013] When the first moisture content is greater than the first threshold, the concrete is in a first quality state;
[0014] When the first moisture content is less than the second threshold, the concrete is in a second quality state;
[0015] When the first moisture content is between the first threshold and the second threshold, the concrete is in a third quality state;
[0016] Wherein, the first quality state and the second quality state are the abnormal quality states, and the third quality state is the normal quality state.
[0017] Optionally, after sending the first warning information to the receiving terminal, the process includes:
[0018] When the first moisture content is greater than the first threshold, the unblocking status of the feed inlet pipe of the mixer is detected by a detection device to obtain detection information;
[0019] When the first moisture content is less than the second threshold, the processing unit obtains a correction value for the concrete based on the difference between the first moisture content and the second threshold, and injects water into the concrete corresponding to the correction value.
[0020] Optionally, the step of detecting the blockage status of the feed pipe of the mixer using a detection device to obtain detection information includes:
[0021] Pressure sensing information is obtained by a pressure sensing unit installed on the feed pipe;
[0022] The system determines whether the feed pipe is blocked by comparing the preset pressure sensor table with the pressure sensor information, thereby obtaining detection information.
[0023] The detection information is sent to the receiving terminal.
[0024] Optionally, the pressure sensing unit includes multiple pressure sensors longitudinally distributed on the wall of the feed pipe, and the detection information includes the unblocking status of the feed pipe and the location and degree of blockage in the event of blockage.
[0025] Optionally, the step of injecting water into the concrete corresponding to the correction value includes:
[0026] The processing unit outputs a signal to the switch actuator to control the water pump to inject water into the water supply branch;
[0027] The processing unit controls the switching of the electric valve to adjust the amount of water injected.
[0028] The water inflow is measured by a metering unit installed at the water inlet, and the cumulative water injection is obtained through the measurement. Water injection stops when the cumulative water injection is the same as the correction value.
[0029] Optionally, the step of stopping water addition when the cumulative water injection volume is the same as the correction value includes:
[0030] Obtain the second moisture content of the concrete and determine the quality state of the concrete at this time;
[0031] When the concrete is in the abnormal quality state, a second warning message is sent to the receiving terminal.
[0032] Optionally, the monitoring unit includes a temperature sensor, a humidity sensor, and a density sensor, and acquiring the first monitoring data of the concrete includes:
[0033] The temperature detection data is obtained by a temperature sensor.
[0034] The humidity detection data is obtained through a humidity sensor;
[0035] The density detection data is obtained through a density sensor.
[0036] Optional,
[0037] The processing unit includes a PLC programmable controller.
[0038] Secondly, this application provides a monitoring system for the state of concrete inside a mixer, comprising:
[0039] The monitoring module is used to acquire first monitoring data of the concrete, which includes temperature monitoring data, humidity monitoring data and density monitoring data of the concrete.
[0040] The processing module is used to process the temperature detection data, humidity detection data, and density detection data through the processing unit and generate the quality status of the concrete.
[0041] The control module is used to acquire second monitoring data of the concrete when the concrete is in an abnormal quality state, and send a first warning message to the receiving terminal, wherein the second monitoring data includes video monitoring data of the concrete.
[0042] In summary, this application includes the following beneficial technical effects:
[0043] The monitoring unit acquires first monitoring data of the concrete, including temperature, humidity, and density monitoring data. The processing unit processes the temperature, humidity, and density data to generate the concrete's quality status. When the concrete is in an abnormal quality state, second monitoring data is acquired, and a first warning message is sent to the receiving terminal. The second monitoring data includes video monitoring data of the concrete. This application achieves real-time monitoring of the concrete state inside the mixer and can detect and issue warnings when the concrete state is abnormal, making it suitable for widespread application. Attached Figure Description
[0044] Figure 1 This is a flowchart illustrating a method for monitoring the state of concrete inside a mixer according to this application.
[0045] Figure 2 This is a flowchart illustrating a concrete condition monitoring method in one embodiment of this application.
[0046] Figure 3 This is a structural schematic diagram of the concrete condition monitoring system inside the mixer of this application. Detailed Implementation
[0047] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of this application.
[0048] This application discloses a method for monitoring the state of concrete inside a mixer.
[0049] Reference Figure 1 and Figure 2 The method includes:
[0050] S10. Obtain first monitoring data of the concrete through the monitoring unit. The first monitoring data includes temperature monitoring data, humidity monitoring data and density monitoring data of the concrete.
[0051] The monitoring unit includes a temperature sensor, a humidity sensor, and a density sensor. All of these sensors are equipped with internet communication modules. Each sensor is placed around the discharge port inside the mixing chamber. By contacting the concrete, the sensors obtain real-time temperature, humidity, and density data of the concrete and transmit the data to the processing unit in a timely manner. After processing, the state of the concrete inside the mixing chamber is obtained, enabling real-time detection of the concrete state.
[0052] By acquiring real-time data on temperature, humidity, and density within the concrete, not only can the water content of the concrete be obtained, but also various basic data on the state of the concrete can be obtained intuitively, facilitating reference for operators.
[0053] The detection unit can be started manually, or it can be programmed based on historical data and automatically start when the preset start conditions are met. It can also be started when a monitoring command is received. All of these can be selected according to the actual needs of the scenario, and no specific restrictions are imposed here.
[0054] S20. The processing unit processes the temperature detection data, humidity detection data, and density detection data to generate the quality status of the concrete.
[0055] Specifically, the process of processing the temperature detection data, humidity detection data, and density detection data through the processing unit to determine the quality status of the concrete includes:
[0056] S21. The temperature detection data, humidity detection data and density detection data are processed by the processing unit to obtain the first moisture content of the concrete.
[0057] Typically, the quality of concrete can be determined by slump testing, but this requires sampling, testing, and inspection, which is cumbersome, time-consuming, and cannot be obtained in real time. This application uses moisture content, which is positively correlated with the quality of concrete, as the criterion. By monitoring relevant data, the quality of concrete can be accurately determined in real time, thus improving monitoring efficiency.
[0058] Specifically, the range of water content of concrete under standard quality conditions is obtained through experimental calculation, and the data is recorded and archived. A table comparing the quality condition of concrete with its water content is established, so as to determine the quality condition of concrete by calculating its water content.
[0059] The processing module includes a programmable logic controller (PLC). The PLC generates the first moisture content of the concrete by processing temperature, humidity, and density data.
[0060] S221. The first moisture content is compared with the first threshold and the second threshold to determine the quality status of the concrete.
[0061] S222 specifically includes:
[0062] S2221. When the first moisture content is greater than the first threshold, the concrete is in a first quality state;
[0063] The first quality state is an abnormal quality state.
[0064] Understandably, when the initial moisture content of concrete exceeds the first threshold, the concrete becomes too wet, leading to seepage and segregation, which severely affects its quality. For example, the moisture content of C40 concrete under normal quality conditions is 3%~5%, the first threshold is 5%, the second threshold is 3%, and the initial moisture content is 6%.
[0065] Step S30: When the concrete is in the first quality state, acquire the second monitoring data of the concrete and send the first early warning information to the receiving terminal.
[0066] By monitoring the interior of a concrete batching plant via video surveillance, the monitoring device can observe the state, fluidity, viscosity, and other workability properties of the concrete to determine whether the aggregate mixing is uniform and whether the water-cement ratio is controlled as expected. Emergency control measures can be implemented when large aggregate clumps adhere to the concrete, or when the concrete is too thin or too dry, to ensure the quality of the concrete.
[0067] When the water content of concrete is too high, video monitoring data of the concrete is acquired and a first warning message is sent to the receiving terminal. Abnormal information and on-site video monitoring information can be sent to the staff at the receiving terminal. Based on the first warning message, the operator can determine the most suitable solution for the current situation of excessive water content in the concrete.
[0068] Understandably, the receiving terminal can be a control console in the central control room or a mobile communication terminal for designated personnel.
[0069] This application can also optimize the way warning information is sent, and can send warning information in multiple time periods, and increase the sending frequency of warning information as the reception duration increases, so that the connected terminal can receive the warning information more reliably.
[0070] Optionally, the processing unit is connected to the audible and visual alarm on the control panel. When an abnormal quality condition occurs, the processing unit controls the audible and visual alarm to generate an audible and visual alarm signal.
[0071] Specifically, the video monitoring information sent to the connected terminal can include the current video monitoring information of the concrete, or it can be preset video information containing a certain time period at the current time point, or it can be video monitoring information with a time period set by the staff of the receiving terminal.
[0072] Optionally, temperature detection data, humidity detection data, density detection data, and video monitoring data are all stored in the storage unit and can be retrieved by staff at any time.
[0073] S41. The blockage status of the feed inlet pipe of the mixer is detected by a detection device to obtain detection information.
[0074] In this process, the raw materials for concrete are put into the mixing chamber of the mixer according to the predetermined raw material ratio. When the water content of the concrete is high, it should be considered whether the feed inlet pipe is blocked. The above method can detect the blockage of the feed inlet pipe by inspecting it, and can promptly and efficiently investigate any possible abnormalities.
[0075] Specifically, the step of detecting the blockage status of the mixer's feed pipe using a detection device to obtain detection information includes:
[0076] Pressure sensing information is obtained by a pressure sensing unit installed on the feed pipe;
[0077] The system determines whether the feed pipe is blocked by comparing the preset pressure sensor table with the pressure sensor information, thereby obtaining detection information.
[0078] The detection information is sent to the receiving terminal.
[0079] When the feed pipe becomes blocked, the system can compare the pressure sensor information with the preset pressure sensor gauge to determine whether a blockage has occurred, and send the detection information to the connection terminal, thereby improving the processing efficiency in abnormal situations.
[0080] Optionally, a pressure rheostat can be installed on the feed pipe, and the presence of a blockage in the feed pipe can be determined by detecting the change in the current of the pressure rheostat.
[0081] Optionally, the pressure sensing unit includes multiple pressure sensors longitudinally distributed on the wall of the feed pipe, and the detection information includes the unblocking status of the feed pipe and the location and degree of blockage in the event of blockage.
[0082] Optionally, when the mixer conveys raw materials through multiple feed pipes, multiple pressure sensors distributed longitudinally are installed on each feed pipe.
[0083] When the first moisture content of the concrete is greater than the first threshold, if a blockage occurs, the condition of the blockage can be accurately determined by the pressure sensors distributed on each feed pipe.
[0084] By distributing multiple pressure sensors along multiple longitudinal directions on the wall of the feed pipe, the location and condition of blockages can be effectively detected, allowing operators at the connection terminal to understand the on-site situation of the mixer and take appropriate actions.
[0085] Furthermore, when a blockage occurs, a clearing device installed on the feed pipe can automatically clear the blockage, thereby enabling a smart and efficient response to the blockage.
[0086] Optionally, after automatic unblocking, the moisture content of the concrete is obtained at this time. If the moisture content returns to the preset range, a warning cancellation signal is sent to the connected terminal.
[0087] S2222 When the first moisture content is less than the second threshold, the concrete is in a second quality state.
[0088] Understandably, when the initial moisture content of concrete is less than the first threshold, the concrete moisture content is too high, leading to seepage and segregation, which severely affects the quality of the concrete. For example, the moisture content of C40 concrete under normal quality conditions is 3%~5%, the first threshold is 5%, the second threshold is 3%, and the initial moisture content is 2.5%.
[0089] S30. When the concrete is in a first quality state, acquire second monitoring data of the concrete and send a first warning message to the receiving terminal. The second monitoring data includes video monitoring data of the concrete.
[0090] S42. Based on the difference between the first moisture content and the second threshold, the processing unit obtains the correction value of the concrete and injects water corresponding to the correction value into the concrete.
[0091] For example, if the moisture content of C40 concrete under normal quality conditions is 3%~5%, the first threshold is 5%, the second threshold is 3%, and the first moisture content is 2.5%, then the corresponding difference is 0.5%. The processing unit obtains the corresponding amount of water that needs to be added and injects water into the concrete accordingly.
[0092] Optionally, the step of injecting water into the concrete corresponding to the correction value includes:
[0093] The processing unit outputs a signal to the switch actuator to control the water pump to inject water into the water supply branch;
[0094] The processing unit controls the switching of the electric valve to adjust the amount of water injected.
[0095] The water inflow is measured by a metering unit installed at the water inlet, and the cumulative water injection is obtained through the measurement. Water injection stops when the cumulative water injection is the same as the correction value.
[0096] The above method enables intelligent and precise control of the injected water volume.
[0097] It is understandable that a new round of mixing is required when or after water is injected into the concrete. The specific mixing time can be set according to the actual situation, and no specific restrictions are made here.
[0098] Optionally, the step of stopping water addition when the cumulative water injection volume is the same as the correction value includes:
[0099] Obtain the second moisture content of the concrete and determine the quality state of the concrete at this time;
[0100] When the concrete is in the abnormal quality state, a second warning message is sent to the receiving terminal.
[0101] The concrete quality status is determined by a second test of its moisture content. If the concrete is still in an abnormal quality state, a second warning message is sent to the receiving terminal.
[0102] Optionally, when the second moisture content is within a preset range, a warning cancellation signal is sent to the connected terminal, thereby realizing intelligent and efficient monitoring of abnormal concrete quality conditions.
[0103] In the above Figures 1-2 The embodiments illustrate in detail the method for monitoring concrete inside the mixer. The following embodiments describe the concrete detection system inside the mixer. Figure 3 The present application discloses a monitoring system 5 for the state of concrete inside a mixer, comprising:
[0104] Monitoring module 51 is used to acquire first monitoring data of the concrete, the first monitoring data including temperature monitoring data, humidity monitoring data and density monitoring data of the concrete;
[0105] Processing module 52 is used to process the temperature detection data, humidity detection data and density detection data and generate the quality status of the concrete;
[0106] The control module 53 is used to acquire second monitoring data of the concrete when the concrete is in an abnormal quality state, and send first early warning information to the receiving terminal, wherein the second monitoring data includes video monitoring data of the concrete.
[0107] The principle of this application is as follows: a monitoring unit acquires first monitoring data of the concrete, including temperature, humidity, and density monitoring data; a processing unit processes the temperature, humidity, and density data to generate the quality status of the concrete; when the concrete is in an abnormal quality state, second monitoring data is acquired, and a first warning message is sent to the receiving terminal, wherein the second monitoring data includes video monitoring data of the concrete. This application realizes real-time monitoring of the concrete status inside the mixer and can detect and issue warnings when the concrete status is abnormal, making it suitable for widespread application and operation.
[0108] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
Claims
1. A method of monitoring the internal concrete condition of a mixer, characterized in that, include: The first monitoring data of the concrete is obtained through the monitoring unit. The first monitoring data includes the temperature monitoring data, humidity monitoring data and density monitoring data of the concrete. The processing unit processes the temperature monitoring data, humidity monitoring data, and density monitoring data to determine the quality state of the concrete, including: processing the temperature monitoring data, humidity monitoring data, and density monitoring data to obtain a first moisture content of the concrete; comparing the first moisture content with a first threshold and a second threshold to determine the quality state of the concrete, wherein the first threshold is 5% and the second threshold is 3%; when the first moisture content is greater than the first threshold, the concrete is in a first quality state; when the first moisture content is less than the second threshold, the concrete is in a second quality state; when the first moisture content is between the first threshold and the second threshold, the concrete is in a third quality state; wherein the first quality state and the second quality state are abnormal quality states, and the third quality state is a normal quality state; When the concrete is in an abnormal quality state, the second monitoring data of the concrete is acquired, and a first early warning message is sent to the receiving terminal, wherein the second monitoring data includes video monitoring data of the concrete; When the first moisture content is greater than a first threshold, the detection device detects the blockage status of the mixer feed pipe to obtain detection information, including: obtaining pressure sensing information through a pressure sensing unit installed on the feed pipe; determining whether the feed pipe is blocked based on a comparison between a preset pressure sensing table and the pressure sensing information to obtain detection information; and sending the detection information to the receiving terminal; wherein, the pressure sensing unit includes multiple pressure sensors longitudinally distributed on the wall of the feed pipe, and the detection information includes the blockage status of the feed pipe and the location and degree of blockage when blockage occurs; When a blockage is detected in the feed pipe, the blockage is automatically cleared by a clearing device installed on the feed pipe. After automatic unblocking, the moisture content of the concrete is obtained. If the moisture content returns to the preset range, a warning cancellation signal is sent to the connected terminal.
2. The monitoring method according to claim 1, characterized in that, After sending the first warning information to the receiving terminal, the following steps are included: When the first moisture content is less than the second threshold, the processing unit obtains a correction value for the concrete based on the difference between the first moisture content and the second threshold, and injects water into the concrete corresponding to the correction value.
3. The monitoring method according to claim 2, characterized in that, The amount of water injected into the concrete corresponding to the correction value includes: The processing unit outputs a signal to the switch relay to control the water pump to inject water into the water supply branch; The processing unit controls the switching of the electric valve to adjust the amount of water injected. The water inflow is measured by a metering unit installed at the water inlet, and the cumulative water injection is obtained through the measurement. Water injection stops when the cumulative water injection is the same as the correction value.
4. The monitoring method according to claim 3, characterized in that, The step of stopping water addition when the cumulative water injection volume is the same as the correction value includes: Obtain the second moisture content of the concrete and determine the quality state of the concrete at this time; When the concrete is in the abnormal quality state, a second warning message is sent to the receiving terminal.
5. The monitoring method of claim 1, wherein, The monitoring unit includes a temperature sensor, a humidity sensor, and a density sensor. Acquiring the first monitoring data of the concrete includes: The temperature monitoring data is acquired by a temperature sensor. The humidity monitoring data is acquired using a humidity sensor; The density monitoring data is obtained through a density sensor.
6. The monitoring method according to claim 1, characterized in that, The processing unit includes a PLC programmable controller.
7. A system for monitoring the condition of concrete inside a mixer, characterized in that The monitoring method according to any one of claims 1-6 includes: The monitoring module is used to acquire first monitoring data of the concrete, which includes temperature monitoring data, humidity monitoring data and density monitoring data of the concrete. The processing module is used to process the temperature monitoring data, humidity monitoring data, and density monitoring data through the processing unit and generate the quality status of the concrete. The control module is used to acquire second monitoring data of the concrete when the concrete is in an abnormal quality state, and send a first warning message to the receiving terminal, wherein the second monitoring data includes video monitoring data of the concrete.