A movable constant-voltage constant-current pavement grouting system and control method

Abstract

The application provides a movable constant-pressure and constant-flow pavement grouting system and a control method, which comprises a moving module, a control module, a grouting module and a monitoring module arranged on the moving module; the control module comprises a frequency conversion control unit and a PLC system; the PLC system receives slurry flow and slurry pressure monitored by a turbine flowmeter and a pressure transmitter, and compares the slurry flow and the slurry pressure with set flow and pressure values; when the monitored slurry flow or slurry pressure reaches the set flow or pressure value, the PLC system controls the frequency conversion control unit, and then regulates and controls the grouting pressure or grouting flow rate of the grouting module. The system can realize single-pump single-liquid constant-pressure pavement grouting and constant-flow pavement grouting under low pressure, and the two pavement grouting modes can be adjusted according to requirements, and the system can realize the function of conveniently grouting at multiple positions on the pavement.

Description

Technical Field

[0001] This invention belongs to the field of grouting technology, and particularly relates to a movable constant pressure and constant flow road grouting system and control method. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] During road construction, roadbed settlement problems are often encountered due to quicksand, uneven backfill, etc. Construction in these areas can cause water and mud inrushes, thus requiring grouting of the road surface. Similarly, after long-term use and exposure to overloading, heavy rain and snow, cracks, broken slabs, or even collapses may appear on the original road surface, reducing its load-bearing capacity. Grouting is also necessary to improve the road surface's load-bearing capacity.

[0004] During road grouting, grouting pressure and flow rate have a significant impact on the grouting effect. Existing constant-pressure grouting systems can provide stable grouting pressure, but due to geological factors such as soil layers, the spatial distribution of grout volume may be uneven, significantly reducing the grouting effect. Existing constant-flow grouting systems can provide stable grouting flow, but in areas with high resistance, the grouting pressure may suddenly increase, also resulting in unsatisfactory grouting results. Therefore, further improvements are needed to achieve integrated low-pressure, single-liquid constant-pressure grouting and constant-flow grouting in road grouting devices, with the ability to switch between them at will. Summary of the Invention

[0005] To overcome the shortcomings of the prior art, the present invention provides a mobile constant pressure and constant flow road grouting system and control method, which can realize single-pump single liquid constant pressure road grouting and constant flow road grouting under low pressure. The two road grouting methods can be adjusted according to needs, and the system can be conveniently moved to grout multiple locations on the road surface.

[0006] To achieve the above objectives, a first aspect of the present invention provides a movable constant pressure and constant flow road grouting system, comprising a movable module, a control module, a grouting module, and a monitoring module disposed on the movable module;

[0007] The control module includes a frequency converter control unit and a PLC system. The PLC system receives the slurry flow rate and slurry pressure monitored by the turbine flow meter and the pressure transmitter, and compares them with the set flow rate value and the set pressure value. When the monitored slurry flow rate or slurry pressure reaches the set flow rate value or the set pressure value, the PLC system controls the frequency converter control unit to regulate the grouting of the grouting module.

[0008] The grouting module includes a screw pump that provides power for grouting, and the frequency conversion control unit controls the power output of the screw pump, thereby regulating the grouting pressure or grouting flow rate.

[0009] The monitoring module, including a turbine flow meter and a pressure transmitter, is located at the outlet of the screw pump.

[0010] A second aspect of the present invention provides a movable constant pressure and constant flow road grouting control method, comprising:

[0011] When constant flow grouting is used, the PLC system receives the grout flow rate monitored by the turbine flow meter. When the monitored grout flow rate reaches the set flow rate value, the PLC system controls the variable frequency control unit to adjust the power output of the screw pump to reduce the grouting flow rate.

[0012] When constant pressure grouting is used, the PLC system receives the grout pressure monitored by the pressure transmitter. When the monitored grout pressure reaches the set pressure value, the PLC system controls the variable frequency control unit to regulate the power output of the screw pump so that the grouting flow rate is maintained at the set pressure value.

[0013] The above one or more technical solutions have the following beneficial effects:

[0014] In this invention, by setting up a control module, a grouting module, and a monitoring module, the control module receives the grout flow rate and grout pressure monitored by the turbine flow meter and the pressure transmitter, and compares them with the set flow rate value and the set pressure value. When the monitored grout flow rate or grout pressure reaches the set flow rate value or the set pressure value, the grouting module adjusts the grouting pressure or flow rate, which can realize single-pump single-liquid constant pressure road grouting and constant flow road grouting under low pressure. Moreover, the two road grouting methods can be adjusted according to needs, and the function of conveniently moving to grout multiple locations on the road surface can be realized.

[0015] Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0016] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0017] Figure 1 This is a schematic diagram of the movable constant pressure and constant flow road grouting device system in Embodiment 1 of the present invention;

[0018] Figure 2This is a schematic diagram of the movable constant pressure and constant flow road grouting device system in Embodiment 1 of the present invention;

[0019] Figure 3 This is a top view of the movable constant pressure and constant flow road grouting device system in Embodiment 1 of the present invention.

[0020] Figure 4 This is a front view of the movable constant pressure and constant flow road grouting device system in Embodiment 1 of the present invention;

[0021] In the diagram, 1. Variable frequency control unit; 2. PLC system; 3. Screw pump; 4. Grout tank; 5. Turbine flow meter; 6. Pressure transmitter; 7. Road grouting point; 8. Four-wheel steel frame box; 9. USB interface; 10. Switch; 11. Emergency stop; 12. Normal operation indicator light; 13. Stop indicator light; 14. Fault reporting indicator light; 15. Grout inlet pipe; 16. Grout outlet pipe; 17. Heat dissipation window; 18. Grouting pipeline; 19. Display; 20. Variable frequency motor; 21. Variable frequency controller. Detailed Implementation

[0022] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0023] It should be noted that the terminology used herein is for the purpose of describing particular implementations only and is not intended to limit the exemplary implementations of the present invention.

[0024] Where there is no conflict, the embodiments and features in the embodiments of the present invention can be combined with each other.

[0025] Example 1

[0026] This embodiment discloses a movable constant pressure and constant flow road grouting system, including a movable module, a control module, a grouting module and a monitoring module disposed on the movable module;

[0027] The control module includes a frequency converter control unit 1 and a PLC system 2. The PLC system 2 receives the slurry flow rate and slurry pressure monitored by the turbine flow meter 5 and the pressure transmitter 6, and compares them with the set flow rate value and the set pressure value. When the monitored slurry flow rate or slurry pressure reaches the set flow rate value or the set pressure value, the PLC system 2 controls the frequency converter control unit 1, thereby regulating the grouting of the grouting module.

[0028] The grouting module includes a screw pump 3 that provides power for grouting, and the frequency conversion control unit 1 controls the power output of the screw pump 3, thereby regulating the grouting pressure or grouting flow rate.

[0029] The monitoring module, including a turbine flow meter 5 and a pressure transmitter 6, is located at the outlet of the screw pump 3.

[0030] Combination Figures 1-4 This embodiment provides a detailed description of a mobile constant pressure and constant flow road grouting system, which includes: a control module consisting of a frequency conversion control unit 1, a PLC system 2, and a display 19; a monitoring module consisting of a turbine flow meter 5 and a pressure transmitter 6; a grouting module consisting of a screw pump 3, an inlet pipe 15, an outlet pipe 16, and an grouting pipeline 18; and a mobile frame with a four-wheel steel frame box 8 as the main body.

[0031] The control module connects the grouting module and the monitoring module. It receives signals from the monitoring module and controls the grouting pressure or flow rate by adjusting the frequency of the variable frequency motor to drive the screw pump 3 in the grouting module. The monitoring module monitors the grouting pressure and flow rate and transmits them to the control module. The grouting module is controlled by the control module to change the power of the pumping grout. The mobile frame is a four-wheeled steel frame box that carries and protects the control module, grouting module, and monitoring module, making it easy to move and transport on the road.

[0032] In this embodiment, the control module includes a frequency converter control unit 1, a PLC system 2, and a display 19. The frequency converter control unit 1 includes a frequency converter motor 20 and a frequency converter controller 21. The frequency converter control unit 1 is connected to the screw pump 3 and the PLC system 2 through a control line. The frequency converter control unit 1 receives signals transmitted by the PLC system 2, and the frequency converter controller 21 changes the frequency of the frequency converter motor 20. In turn, the frequency converter motor 20 regulates the power output of the screw pump 3 to complete the regulation of grouting flow rate or pressure.

[0033] The PLC system 2 receives the flow rate and pressure of the slurry from the turbine flow meter 5 and the pressure transmitter 6, and compares them with the pressure set value or flow set value set on the display 19 interface. The comparison result is transmitted to the frequency converter control unit 1, which sends a control signal to the frequency converter controller 21 to adjust the grouting.

[0034] The display 19 is connected to the PLC system 2 via a signal. The display 19 provides an interactive interface with the PLC system 2. The display 19 displays the pressure setpoint, flow setpoint, overpressure protection, overpressure delay, etc., and displays the real-time pressure, real-time flow, and cumulative flow read by the PLC system 2. The display 19 also retrieves and saves previous data through the USB interface 9, which facilitates the planning and execution of road grouting work.

[0035] The grouting module includes a screw pump 3, a grout inlet pipe 15, a grout outlet pipe 16, and a grouting pipeline 18. The screw pump 3 is electrically connected to a variable frequency motor 20, with a maximum flow rate of 0.8 m³ / h, a head of 120 m, a motor power of 2.2 kW, and a voltage of 380 V, providing power to extract and pump the grout. The grout inlet pipe 15 extracts grout from the grout tank 4 and connects to the screw pump 3 through a four-wheel steel frame box 8. The grout outlet pipe 16 connects to the four-wheel steel frame box 8 to inject the grout into the road grouting point 7. The grouting pipeline 18 is the pipeline for transporting the grout from the screw pump to the grout outlet pipe. A turbine flow meter 5 and a pressure transmitter 6 are connected to the grouting pipeline 18.

[0036] The monitoring module includes a turbine flow meter 5 and a pressure transmitter 6, both installed on the grouting pipeline 18. The turbine flow meter 5 has a diameter of DN6, a range of 0.1-0.6 m³ / h, an output signal of 4-20 mA, an operating pressure of ≤6.3 MPa, and an accuracy class of 1.0. The pressure transmitter 6 has a range of 0-1.6 MPa, an output signal of 4-20 mA, and an accuracy class of 0.5. It monitors the flow and pressure in the grouting pipeline 18 in real time and transmits the data to the PLC system 2 at a frequency of 10 Hz.

[0037] The mobile frame is a four-wheeled steel frame box 8, with dimensions of 145cm in length, 70cm in width, and 80cm in height. The wheels are 16cm high. The front of the four-wheeled steel frame box 8 is equipped with a frequency converter controller 21, a PLC system 2, a display 19, and a slurry outlet. The back of the box provides a slurry inlet and a heat dissipation window 17. The box body of the four-wheeled steel frame box 8 is supported by four omnidirectional wheels that can slide in any direction. The four-wheeled steel frame box 8 is used to carry and protect the control module, grouting module, monitoring module, and to move and transport the entire system device.

[0038] Example 2

[0039] This embodiment provides a movable constant pressure and constant flow road grouting control method, employing a movable constant pressure and constant flow road grouting system as described in Embodiment 1, comprising:

[0040] When constant flow grouting is used, the PLC system receives the grout flow rate monitored by the turbine flow meter. When the monitored grout flow rate reaches the set flow rate value, the PLC system controls the variable frequency control unit to adjust the power output of the screw pump to reduce the grouting flow rate.

[0041] When constant pressure grouting is used, the PLC system receives the grout pressure monitored by the pressure transmitter. When the monitored grout pressure reaches the set pressure value, the PLC system controls the variable frequency control unit to regulate the power output of the screw pump so that the grouting flow rate is maintained at the set pressure value.

[0042] In this embodiment, specifically, when the constant pressure grouting method is used, the grout is introduced from the grout tank 4 into the screw pump 3 through the grout inlet pipe 15. A pressure set value, a shutdown flow rate, and a shutdown flow rate delay are set on the display 19 interface. Overpressure protection and overpressure delay are also set to avoid unnecessary interruptions and protect the entire device. Grouting is started by the switch 10. When the real-time pressure monitored by the pressure transmitter 6 and transmitted to the PLC system 2 and the display 19 interface reaches the pressure set value, the frequency converter 21 will adjust the frequency converter motor 20 and thus control the power output of the screw pump 3 to reduce the grouting flow rate and keep the grouting pressure below the pressure set value. To reduce the impact of sudden pressure changes caused by motor control errors, grouting will automatically stop when the grouting flow rate reaches the shutdown flow rate and the duration reaches the shutdown flow rate delay set time.

[0043] When using the constant pressure grouting method, the motor starts running at full power, and pressure monitoring is activated. When the monitored grouting pressure reaches 90% of the set pressure, the PLC starts controlling the frequency converter to reduce the motor frequency, and simultaneously activates flow monitoring. Based on the monitored pressure data, the PLC predicts the required motor frequency within 0.5 seconds using an extrapolation function, and continuously corrects the motor output frequency at 2Hz based on the real-time monitored pressure to ensure the real-time pressure remains stable around the set value. In summary, during constant pressure grouting, when the real-time pressure reaches 90% of the set value, the motor frequency decreases, the grouting flow rate continuously decreases, and grouting automatically stops when the grouting flow rate reaches the shutdown flow rate and the duration reaches the set shutdown flow rate delay time.

[0044] When using the constant flow grouting method, the grout is introduced from the grout tank 4 into the screw pump 3 through the grout inlet pipe 15. A flow rate set value, protection pressure, and overpressure delay are set on the display 19 interface. The grouting is started by pressing the switch 10. When the real-time flow rate monitored by the turbine flow meter 5 and transmitted to the PLC system 2 and displayed on the display 19 interface reaches the flow rate set value, the frequency converter 21 will adjust the frequency converter motor 20 and thus control the power output of the screw pump 3 to keep the grouting flow rate near this flow rate set value. As the grouting proceeds, the grouting pressure continuously increases. When the grouting pressure reaches the protection pressure and the duration reaches the overpressure delay, the grouting automatically stops.

[0045] When constant flow grouting is used, the motor starts running at full power, and flow monitoring is activated. When the monitored grouting flow reaches 90% of the set flow value, the PLC starts controlling the frequency converter to reduce the motor frequency, and simultaneously activates pressure monitoring. Based on the monitored flow data, the PLC predicts the required motor frequency value within 0.5 seconds using an extrapolation function, and continuously corrects the motor output frequency at a 2Hz frequency based on the real-time monitored flow to ensure the real-time flow remains stable around the set value. In summary, during constant flow grouting, when the real-time pressure reaches 90% of the set value, the grouting pressure increases as grouting progresses. When the grouting pressure reaches the protection pressure and the duration reaches the overpressure delay set value, grouting automatically stops.

[0046] When using the constant pressure grouting method, the overpressure delay is used to prevent grouting from stopping immediately when the grouting pressure reaches the overpressure protection value. Instead, grouting stops when the pressure exceeds the overpressure protection value and the duration reaches the overpressure delay set time, allowing the pressure fluctuation to return to normal, avoiding unnecessary interruptions and protecting the entire device.

[0047] The control method of this system is as follows: Grout is introduced from the grout tank 4 into the screw pump 3 through the grout inlet pipe 15. On the display 19 interface, either pressure control mode or flow control mode is selected. In the pressure control mode interface, the pressure setpoint, shut-off flow rate, shut-off flow rate delay, and overpressure protection and overpressure delay protection devices are set. In the flow control mode interface, the flow rate setpoint is set, and the protection pressure and overpressure delay protection devices are set. After selecting the grouting mode and setting the relevant values, the switch 10 is pressed to start grouting. The PLC system 2 compares the data monitored and read by the turbine flow meter 5 and pressure transmitter 6 with the set values ​​and sends a signal to the frequency converter 21. The frequency converter 21 controls the frequency converter motor 20 to change its frequency, regulating the power output of the screw pump 3 and adjusting the grouting pressure or flow rate until the shut-off flow rate or protection pressure is reached and the duration reaches the set shut-off flow rate delay or overpressure delay, at which point grouting automatically stops.

[0048] During the grouting process, observe the status of the normal operation indicator 12, the stop indicator 13, and the fault reporting indicator 14. After pressing the switch 10 for the first time, the normal operation indicator 12 will light up, indicating normal operation. If the fault reporting indicator 14 lights up, press the emergency stop 11 to stop the operation. After pressing the switch 10 for the second time, the stop indicator 13 will light up.

[0049] In this embodiment, grouting can be terminated in advance or repeated based on the cumulative flow displayed on the display 19 interface. After grouting one section of the road surface, it can be moved to the next section of the road surface that needs grouting via the four-wheeled steel frame box 8.

[0050] Those skilled in the art will understand that the modules or steps of the present invention described above can be implemented using general-purpose computer devices. Optionally, they can be implemented using computer-executable program code, thereby allowing them to be stored in a storage device for execution by a computer device, or they can be fabricated as separate integrated circuit modules, or multiple modules or steps can be fabricated as a single integrated circuit module. The present invention is not limited to any particular combination of hardware and software.

[0051] While the specific embodiments of the present invention have been described above in conjunction with the accompanying drawings, this is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art without creative effort based on the technical solutions of the present invention are still within the scope of protection of the present invention.

Claims

1. A movable, constant-pressure, constant-flow road grouting method, characterized in that, include: A mobile module, comprising a control module, a grouting module, and a monitoring module mounted on the mobile module; The control module includes a frequency converter control unit and a PLC system. The PLC system receives the slurry flow rate and slurry pressure monitored by the turbine flow meter and pressure transmitter, and compares them with the set flow rate value and set pressure value. When the monitored slurry flow rate or slurry pressure reaches the set flow rate value or set pressure value, the PLC system controls the frequency converter control unit to regulate the grouting of the grouting module. The grouting module includes a screw pump that provides power for grouting, and the frequency conversion control unit controls the power output of the screw pump, thereby regulating the grouting pressure or grouting flow rate. The monitoring module, including a turbine flow meter and a pressure transmitter, is located at the outlet of the screw pump. When constant flow grouting is used, the PLC system receives the grout flow rate monitored by the turbine flow meter. When the monitored grout flow rate reaches the set flow rate value, the PLC system controls the variable frequency control unit to adjust the power output of the screw pump to reduce the grouting flow rate. When constant flow grouting is used, the PLC system predicts the motor output frequency value through an extrapolation function based on the received grouting flow value, and corrects the motor output frequency based on the real-time monitored grouting flow value, so that the grouting flow value is stable around the set flow value. When constant flow grouting is used, grouting stops when the grouting pressure reaches the protection pressure and the duration reaches the overpressure delay set value; When constant pressure grouting is used, the PLC system receives the grout pressure monitored by the pressure transmitter. When the monitored grout pressure reaches the set pressure value, the PLC system controls the variable frequency control unit to regulate the power output of the screw pump so that the grouting flow rate is maintained at the set pressure value. When constant pressure grouting is used, the PLC system predicts the motor output frequency value through an extrapolation function based on the received grouting pressure value, and corrects the motor output frequency based on the real-time monitored grouting pressure value, so that the grouting pressure value is stable around the pressure set value. When constant pressure grouting is used, grouting stops when the grouting flow rate reaches the shutdown flow rate and the duration reaches the shutdown flow rate delay set time.

2. The movable constant pressure and constant flow road grouting method as described in claim 1, characterized in that, The variable frequency control unit includes a variable frequency controller and a variable frequency motor. The variable frequency controller receives control signals from the PLC system and regulates the power output of the screw pump by controlling the frequency of the variable frequency motor.

3. The movable constant pressure and constant flow road grouting method as described in claim 1, characterized in that, The control module also includes a display, which is electrically connected to the PLC system. The display is used to display real-time slurry flow rate, real-time slurry pressure, pressure setpoint, flow rate setpoint, overpressure protection, and overpressure delay.

4. The movable constant pressure and constant flow road grouting method as described in claim 1, characterized in that, The grouting module also includes a grout inlet pipe, a grout outlet pipe, and a grouting pipeline. The grout inlet pipe is connected to the grout inlet of the screw pump, and the grout outlet pipe is connected to the grout outlet of the screw pump through the grouting pipeline.

5. A movable constant pressure and constant flow road grouting method as described in claim 4, characterized in that, The turbine flow meter and the pressure transmitter are installed on the grouting pipeline.

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