Method, system, device and storage medium for monitoring the production process of ready-mix concrete

Abstract

The application discloses a premixed plant concrete production process monitoring method, system, equipment and storage medium, the method sends the electric signal, temperature and humidity information and production information to the control host computer, so that the reference test point controls the temperature and humidity of the environment according to the temperature and humidity information, and the working performance index information corresponding to the electric signal and the production information is measured; the mathematical model relationship corresponding to each premixed plant concrete production line is established; the mathematical model relationship is converted into key index information, and a relationship between the real-time electric signal corresponding to the key index information and the key index information is established; the reference value corresponding to the key index information is input into the control terminal, and the premixed plant concrete production process monitoring is carried out according to the relationship between the real-time electric signal and the key index information. The application can monitor the whole process and all equipment of concrete production, has high intelligent degree and carries out targeted debugging optimization on the equipment.

Description

Technical Field

[0001] This invention relates to the field of concrete production monitoring technology, and in particular to a method, system, equipment and storage medium for monitoring the concrete production process in a ready-mixed plant. Background Technology

[0002] Monitoring the concrete production process has always been a top priority for ready-mixed concrete plants. In recent years, with the scarcity of sand and gravel resources and the introduction of the "dual carbon target," efficient and intelligent monitoring of the concrete production process has become a crucial issue for the industry. To address this challenge, existing technologies primarily rely on predicting the slump based on the unit volume of water or water-cement ratio in the mix design, thus enabling production process monitoring. Other methods include establishing data transmission channels to review the construction process for effective monitoring and management throughout the entire process; and constructing an improved CNN-LSTM slump prediction model to solve problems such as high reliance on manual slump monitoring, inability to conduct online monitoring, and low accuracy.

[0003] Analysis of the existing technologies revealed several drawbacks: 1) Limited monitoring scope, monitoring only some processes or equipment; 2) Low level of intelligence and automation in monitoring; 3) Lack of targeted debugging and optimization for different production lines (equipment models, statuses, etc.). Summary of the Invention

[0004] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention proposes a method, system, equipment, and storage medium for monitoring the concrete production process in a ready-mixed concrete plant. This method can monitor the entire concrete production process and all equipment, and features a high degree of intelligence and allows for targeted debugging and optimization of the equipment.

[0005] In a first aspect, embodiments of the present invention provide a method for monitoring the concrete production process at a ready-mixed concrete plant, the method comprising:

[0006] Acquire electrical signals, temperature and humidity information, and production information from multiple ready-mixed concrete production lines;

[0007] The electrical signal, the temperature and humidity information, and the production information are sent to the control host so that the benchmark test point controls the temperature and humidity of the environment according to the temperature and humidity information, and measures the working performance index information corresponding to the electrical signal and the production information.

[0008] Based on the electrical signals, the production information, and the performance index information, establish a mathematical model relationship for each of the ready-mixed concrete production lines in the plant.

[0009] The mathematical model relationship is transformed into key indicator information, and a relationship is established between the real-time electrical signal corresponding to the key indicator information and the key indicator information.

[0010] The reference values ​​corresponding to the key indicator information are input to the control terminal, and the concrete production process of the ready-mixed plant is monitored according to the relationship between the real-time electrical signal and the key indicator information.

[0011] Compared with the prior art, the first aspect of the present invention has the following beneficial effects:

[0012] This method acquires electrical signals, temperature and humidity information, and production data from multiple ready-mix concrete production lines. These data are then transmitted to a control host, allowing benchmark test points to control the ambient temperature and humidity based on the temperature and humidity information. Performance indicators corresponding to the electrical signals and production data are measured. Based on these data, a mathematical model is established for each ready-mix concrete production line. Since each production line differs in equipment, strength grade, mixing volume, and mix proportion, establishing a mathematical model for each production line based on its data can improve the efficiency of ready-mix concrete production. The accuracy of concrete production process monitoring is enhanced by comprehensively considering electrical signals, production information, and performance indicators, resulting in a wide monitoring range. Mathematical model relationships are transformed into key indicator information, and a relationship formula is established between real-time electrical signals and key indicator information. This enables the orderly accumulation of data, aids in tracing the source of production process problems, and contributes to stable production quality and management. Reference values ​​corresponding to key indicator information are input to the control terminal, and the ready-mixed concrete production process is monitored based on the relationship formula between real-time electrical signals and key indicator information. This allows for monitoring of the entire concrete production process and all equipment, exhibiting a high degree of intelligence and enabling targeted debugging and optimization of equipment.

[0013] According to some embodiments of the present invention, establishing a mathematical model relationship corresponding to each ready-mixed concrete production line of the plant based on the electrical signal, the production information, and the performance index information includes:

[0014] Based on the electrical signals, the production information, and the performance indicators, a mathematical model is constructed to establish the relationship between the concrete performance, equipment status, energy consumption and efficiency, abnormal situation tracing, and electrical signals for each ready-mixed concrete production line.

[0015] According to some embodiments of the present invention, the concrete workability includes slump, and the construction of a mathematical model relationship between the concrete workability and the electrical signal includes:

[0016] Calculate the difference between the peak current and the no-load current generated during each batch of concrete mixing at the ready-mix plant;

[0017] When the slump is in a first range, a second range of the difference corresponding to the slump is determined based on the first range, and a mathematical model relationship between the slump and the difference is established based on the first range and the second range.

[0018] According to some embodiments of the present invention, constructing a mathematical model relationship between the device state and the electrical signal includes:

[0019] When the no-load current value of the mixer is greater than the first preset value, it is determined that there is an abnormality in the mixer equipment;

[0020] Calculate the rate of change of current based on the current value at the previous moment and the current value at the current moment;

[0021] When the absolute value of the current change rate is greater than the second preset value, it is determined that there is an abnormality in the mixing process.

[0022] According to some embodiments of the present invention, constructing a mathematical model relationship between the energy consumption and efficiency and the electrical signal includes:

[0023] Calculate the product of current, voltage, and time, and calculate the unit energy consumption based on the product and the stirring volume;

[0024] When the unit energy consumption is greater than the third preset value, it is determined that the production energy consumption and efficiency are abnormal.

[0025] According to some embodiments of the present invention, constructing a mathematical model relationship between the anomaly tracing and the electrical signal includes:

[0026] When an abnormal situation occurs, the source of the abnormal situation is traced by comparing the electrical signal under the abnormal situation with the electrical signal of the normal operation.

[0027] According to some embodiments of the present invention, the step of inputting the reference value corresponding to the key indicator information to the control terminal, and monitoring the ready-mixed concrete production process according to the relationship between the real-time electrical signal and the key indicator information, includes:

[0028] Acquire real-time electrical signals during the concrete production process at a ready-mixed plant;

[0029] The reference values ​​corresponding to the key indicator information are input to the control terminal. Based on the relationship between the real-time electrical signal and the key indicator information, the real-time electrical signal in the concrete production process of the ready-mixed plant is compared with the reference values ​​corresponding to the key indicator information to realize the monitoring of the concrete production process of the ready-mixed plant.

[0030] Secondly, embodiments of the present invention also provide a monitoring system for the concrete production process of a ready-mixed plant, the monitoring system comprising:

[0031] The data acquisition unit is used to acquire electrical signals, temperature and humidity information, and production information from multiple ready-mixed concrete production lines.

[0032] The information acquisition unit is used to send the electrical signal, the temperature and humidity information and the production information to the control host, so that the reference test point controls the temperature and humidity of the environment according to the temperature and humidity information, and measures the working performance index information corresponding to the electrical signal and the production information.

[0033] The model building unit is used to establish the mathematical model relationship corresponding to each of the ready-mixed concrete production lines based on the electrical signal, the production information and the working performance index information.

[0034] The relationship establishment unit is used to convert the mathematical model relationship into key indicator information and establish the relationship between the real-time electrical signal corresponding to the key indicator information and the key indicator information.

[0035] The production monitoring unit is used to input the reference values ​​corresponding to the key indicator information to the control terminal, and to monitor the concrete production process of the ready-mixed plant according to the relationship between the real-time electrical signal and the key indicator information.

[0036] Thirdly, embodiments of the present invention also provide a monitoring device for the concrete production process of a ready-mixed plant, including at least one control processor and a memory for communicatively connecting to the at least one control processor; the memory stores instructions that can be executed by the at least one control processor, the instructions being executed by the at least one control processor to enable the at least one control processor to perform a ready-mixed plant concrete production process monitoring method as described above.

[0037] Fourthly, embodiments of the present invention also provide a computer-readable storage medium storing computer-executable instructions for causing a computer to execute a ready-mixed concrete production process monitoring method as described above.

[0038] It is understood that the beneficial effects of the second to fourth aspects compared with the related technologies are the same as the beneficial effects of the first aspect compared with the related technologies. Please refer to the relevant description in the first aspect above, which will not be repeated here. Attached Figure Description

[0039] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0040] Figure 1 This is a flowchart of a method for monitoring the concrete production process in a ready-mixed plant according to an embodiment of the present invention;

[0041] Figure 2 This is a schematic diagram of the framework of a premixed concrete production process monitoring method according to another embodiment of the present invention;

[0042] Figure 3 This is a schematic diagram illustrating the mathematical model relationship between collapse degree and electrical signal according to an embodiment of the present invention;

[0043] Figure 4 This is a schematic diagram of the control terminal input according to an embodiment of the present invention;

[0044] Figure 5 This is a structural diagram of a premixed concrete production process monitoring system according to an embodiment of the present invention;

[0045] Figure 6 This is a schematic diagram of the structure of an electronic device according to an embodiment of the present invention. Detailed Implementation

[0046] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0047] In the description of this invention, the use of terms such as "first," "second," etc., is for the purpose of distinguishing technical features only and should not be construed as indicating or implying relative importance, or implicitly indicating the number of technical features indicated, or implicitly indicating the order of the technical features indicated.

[0048] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, etc., are based on the orientation or positional relationship shown in the drawings and are only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0049] In the description of this invention, it should be noted that, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0050] The existing technology has several drawbacks: 1) the monitoring scope is limited, only monitoring some processes or some equipment; 2) the level of intelligence and automation of the monitoring is low; 3) it has not been specifically debugged and optimized for different production lines (equipment models, status, etc.).

[0051] To address the aforementioned problems, this invention acquires electrical signals, temperature and humidity information, and production information from multiple ready-mix concrete production lines. This information is then transmitted to a control host, enabling benchmark test points to control the ambient temperature and humidity based on the temperature and humidity data. Furthermore, it measures the performance indicators corresponding to the electrical signals and production information. Based on these data, a mathematical model is established for each ready-mix concrete production line. Since each production line differs in equipment, strength grade, mixing volume, and mix proportion, establishing a mathematical model for each production line based on its data can improve efficiency. This system improves the accuracy of monitoring the concrete production process at ready-mixed plants, comprehensively considering electrical signals, production information, and performance indicators to achieve a wide monitoring range. It transforms mathematical model relationships into key indicator information and establishes a relationship between real-time electrical signals and key indicator information, enabling the orderly accumulation of data, facilitating the tracing of production process problems, and contributing to stable production quality and management. By inputting reference values ​​corresponding to key indicator information into the control terminal and monitoring the ready-mixed plant concrete production process based on the relationship between real-time electrical signals and key indicator information, it can monitor the entire concrete production process and all equipment, exhibiting a high degree of intelligence and allowing for targeted debugging and optimization of equipment.

[0052] Reference Figure 1 This invention provides a method for monitoring the concrete production process in a ready-mixed concrete plant. This method includes, but is not limited to, steps S100 to S500, wherein:

[0053] Step S100: Obtain electrical signals, temperature and humidity information, and production information from multiple ready-mixed concrete production lines;

[0054] Step S200: Send electrical signals, temperature and humidity information and production information to the control host so that the reference test point controls the temperature and humidity of the environment according to the temperature and humidity information, and measures the working performance index information corresponding to the electrical signals and production information.

[0055] Step S300: Based on electrical signals, production information, and performance indicators, establish the mathematical model relationship corresponding to each ready-mixed concrete production line.

[0056] Step S400: Transform the mathematical model relationship into key indicator information, and establish the relationship between the real-time electrical signal and the key indicator information corresponding to the key indicator information;

[0057] Step S500: Input the reference values ​​corresponding to the key indicator information into the control terminal, and monitor the concrete production process of the ready-mixed plant according to the relationship between the real-time electrical signal and the key indicator information.

[0058] In this embodiment, to improve the accuracy of monitoring the concrete production process at the ready-mixed plant and broaden the monitoring range, this embodiment acquires electrical signals, temperature and humidity information, and production information from multiple ready-mixed plant concrete production lines. These signals, humidity, and production information are then sent to the control host. This allows benchmark test points to control the ambient temperature and humidity based on the temperature and humidity information, and to measure the corresponding performance indicators. Based on the electrical signals, production information, and performance indicators, a mathematical model relationship is established for each ready-mixed plant concrete production line. To facilitate stable production quality and management, and to perform full-process monitoring and improve intelligence, this embodiment transforms the mathematical model relationship into key indicator information and establishes a relationship between the real-time electrical signals and the key indicator information. Reference values ​​corresponding to the key indicator information are input to the control terminal, and the ready-mixed plant concrete production process is monitored based on the relationship between the real-time electrical signals and the key indicator information.

[0059] In some embodiments, a mathematical model relationship is established for each ready-mixed concrete production line based on electrical signals, production information, and performance index information, including:

[0060] Based on electrical signals, production information, and performance indicators, a mathematical model is constructed to establish the relationship between the concrete performance, equipment status, energy consumption and efficiency, abnormal situation tracing, and electrical signals for each ready-mixed concrete production line.

[0061] In this embodiment, since each ready-mixed concrete production line has different equipment, strength grades, mixing volumes, and mix proportions, establishing a mathematical model relationship for each ready-mixed concrete production line based on its data can improve the accuracy of monitoring the ready-mixed concrete production process. Real-time monitoring of equipment status, performance, energy consumption, and energy efficiency can be achieved through various key indicator information, resulting in a broad monitoring scope.

[0062] In some embodiments, concrete workability includes slump, and a mathematical model is constructed to establish the relationship between concrete workability and electrical signals, including:

[0063] Calculate the difference between the peak current and the no-load current generated during each batch of concrete mixing at the ready-mix plant;

[0064] When the slump is in the first range, a second range of the difference corresponding to the slump is determined based on the first range, and a mathematical model relationship between the slump and the difference is established based on the first range and the second range.

[0065] In this embodiment, by establishing a mathematical model relationship between slump and difference, it is possible to monitor whether the slump of concrete in each batch of ready-mixed concrete is abnormal, thereby improving the accuracy of monitoring.

[0066] In some embodiments, constructing a mathematical model relationship between device states and electrical signals includes:

[0067] When the no-load current value of the mixer is greater than the first preset value, it is determined that there is an abnormality in the mixer equipment;

[0068] Calculate the rate of change of current based on the current value at the previous moment and the current value at the current moment;

[0069] When the absolute value of the rate of change of current is greater than the second preset value, it is determined that there is an abnormality in the mixing process.

[0070] In this embodiment, by establishing a mathematical model relationship between the no-load current value and the current change rate of the mixer, it is possible to monitor whether the no-load current of the mixer is abnormal and whether the current change rate is abnormal, thereby monitoring whether there is any abnormality in the equipment and the mixing process, thus improving the accuracy of monitoring.

[0071] In some embodiments, constructing a mathematical model relationship between energy consumption and efficiency and electrical signals includes:

[0072] Calculate the product of current, voltage, and time, and then calculate the unit energy consumption based on the product and the stirring volume.

[0073] When the energy consumption per unit exceeds the third preset value, it is determined that there is an abnormality in production energy consumption and efficiency.

[0074] In this embodiment, by establishing a mathematical model relationship between unilateral energy consumption, it is possible to monitor whether there are any abnormalities in energy consumption and efficiency, thereby improving the accuracy of monitoring.

[0075] In some embodiments, constructing a mathematical model relationship between anomaly tracing and electrical signals includes:

[0076] When an abnormal situation occurs, the source of the abnormal situation can be traced by comparing the electrical signal under the abnormal situation with the electrical signal of the normal cycle.

[0077] In this embodiment, by constructing a mathematical model relationship between anomaly tracing and electrical signals, the source of anomalies can be traced, thereby finding the cause of the anomaly more quickly and improving work efficiency.

[0078] In some embodiments, reference values ​​corresponding to key indicator information are input to the control terminal, and the ready-mixed concrete production process of the plant is monitored based on the relationship between real-time electrical signals and key indicator information, including:

[0079] Acquire real-time electrical signals during the concrete production process at a ready-mixed plant;

[0080] The reference values ​​corresponding to key indicator information are input to the control terminal. Based on the relationship between real-time electrical signals and key indicator information, the real-time electrical signals in the ready-mixed concrete production process are compared with the reference values ​​corresponding to key indicator information to achieve monitoring of the ready-mixed concrete production process.

[0081] In this embodiment, by comparing the real-time electrical signals during the concrete production process of the ready-mix plant with the relationship between the real-time electrical signals and key indicator information, it is possible to automatically monitor whether any abnormalities occur in the concrete production process of the ready-mix plant. It can monitor the entire concrete production process and all equipment, with a high degree of intelligence and targeted debugging and optimization for the equipment.

[0082] To facilitate understanding by those skilled in the art, a set of preferred embodiments is provided below:

[0083] This embodiment describes a ready-mixed concrete plant with two production lines. The concrete production process of the ready-mixed concrete plant with two production lines is monitored according to the following steps:

[0084] S1: Equipment modification and installation. (Refer to...) Figure 2 Two sets of electrical signal acquisition and sensor installations for the mixers will be installed at the existing premix plant, one per production line. One control host, one control terminal, and two display terminals (one per production line) will be installed in the central control room. Specifically:

[0085] Each set of electrical signal acquisition and sensor includes one group of current signal acquisition units (3 units, three-phase, one per phase line), one voltage signal acquisition unit, one temperature and humidity sensor, and one data repeater. Among them, the mixer current signal acquisition unit, voltage signal acquisition unit, and temperature and humidity sensor are connected to the data repeater via wired or wireless means, and the current signal acquisition unit is an AC current transformer.

[0086] The electrical signal acquisition and sensor are installed in the mixer's distribution cabinet. The temperature and humidity sensor is installed at one end of the mixer's discharge port. The electrical signal acquisition and sensor are installed on the outer side and top surface of the mixer's distribution cabinet (with a certain distance maintained to avoid affecting the original circuitry and to meet safety and fire protection requirements). The electrical signal acquisition device directly collects the current and voltage driving the mixer and the opening / closing status (open, half-open, closed) of the mixing chamber door.

[0087] The control host, terminals, and data repeaters are wirelessly connected. The control host and terminals are installed in the central control room of the ready-mixed concrete plant. The control host and terminals are mounted on the desktop of the office desk in the central control room, while the terminals are mounted on the wall. The control host is wirelessly connected to the mixer control console (host), enabling real-time acquisition of production information for each batch of concrete. The mixer control console is the controller for the mixer, a component of the mixer, and is responsible for starting, stopping, and other operations of the mixer. Production information includes the production line number, strength grade, design slump, mixing volume, mix proportion, mixing start time, project name, and transport vehicle number for each batch of concrete.

[0088] The control unit can read, process, and store production information such as current, voltage, temperature, humidity, time, and other data for each batch (one mixing cycle). Current and voltage signals are visualized on the terminal, with time as the horizontal axis and current / voltage ratio as the numerical axis. Temperature and humidity sensor information and the opening / closing status of the mixing chamber door are also displayed on the terminal in real time. The control unit displays information and enables interactive functions through the terminal.

[0089] The terminals are divided into mobile terminals, display terminals, and control terminals, with only the control terminals having human-machine interaction permissions. The display terminals can display, upon selection, electrical signals (current, voltage, etc. changing over time), production information, key indicator information, and early warning information (i.e., reference values) from one or more production lines in real time. Key indicator information includes no-load current (current when the mixer is idling), peak current (maximum current value in a single batch of the mixer), steady-state current (current when the concrete is fully mixed), current difference (peak current - no-load current), current change rate ((current value one second ago - current value at the current time) / 1s), voltage, slope (value is (peak current - steady-state current) / difference in time to reach the corresponding current), time, temperature and humidity, and other values ​​derived from mathematical and physical relationships based on time as a function. Reference values ​​are the range, specific values, or formulas of the aforementioned key indicator information input through the human-machine interaction function of the control terminal.

[0090] S2: Establishment and Testing of Benchmark Test Points. Benchmark test points for concrete workability are established in the ready-mixed concrete laboratory to obtain the workability indicators of freshly mixed concrete. Specifically:

[0091] The benchmark testing point controls the ambient temperature and humidity, maintaining humidity above 60%, temperature between 20±3℃, and ensuring no wind. The benchmark point can be understood as a standard laboratory, effectively controlling the ambient temperature and conducting tests on relevant indicators. The benchmark testing point can test the workability indicators of concrete, including slump, slump flow, plastic viscosity, and static yield stress.

[0092] The performance indicators can be input through the control terminal interface, and correspond one-to-one with the mixer's electrical signals and production information.

[0093] Through S1 and S2, an organic link can be established between the production information, electrical signal information, and work performance information of ready-mixed concrete, forming an information chain.

[0094] The host can export the above data (production information, electrical signal information, and working performance information). It can export by batch, or filter by production information, electrical signal information, and working performance information, or export by conditions, such as exporting data of C30 grade from production line number 1 between October 8th and October 15th with a slump value between 180 and 220 mm.

[0095] S3: Establishment of Mathematical Model Relationships. Based on the collection and analysis of production information, mixing process electrical signals, and performance indicators for each batch of concrete, a mathematical model relationship was established between concrete workability, equipment status, energy consumption and efficiency, anomaly tracing, and electrical signals. Specifically:

[0096] The mathematical model relationships were established considering the effects of different production lines, strength grades, mixing volumes, and mix proportions. The data were categorized and organized according to different production lines, different strength grade ranges, and the same or similar mixing volumes.

[0097] The mathematical model relationship between concrete workability and electrical signal is the relationship between slump (workability) and the difference between peak current and no-load current generated in each batch of mixing. Specifically, when the slump index of the freshly mixed concrete is within a certain range (i.e., the first range), the corresponding electrical signal (i.e., the difference between peak current and no-load current) is also within a certain range (i.e., the second range).

[0098] The mathematical model relationship between equipment status and electrical signals is as follows: when the no-load current value of the mixer is greater than a certain value (i.e., the first preset value), the mixer equipment is considered to be malfunctioning. The mathematical model relationship between equipment status and electrical signals is also determined by whether there is a sharp decrease in current or voltage values. Specifically, when the absolute value of the current change rate ((current value in the previous second - current value in the current time) / 1s) is greater than a certain value (i.e., the second preset value), the mixing process is judged to be malfunctioning.

[0099] The mathematical model relationship between energy consumption, efficiency, and electrical signals is as follows: when the unit energy consumption (the product of current, voltage, and time (W = UIT) / stirring volume) exceeds a certain value (i.e., the third preset value), an abnormal production energy consumption is alerted.

[0100] The mathematical model relationship between abnormal situations and electrical signals is as follows: When abnormal concrete slump, abnormal mixer no-load current, abnormal current change rate, and abnormal energy consumption occur (including but not limited to), the cause can be found by comparing the differences (numerical magnitude, graphic shape, range, etc.) between the abnormal and normal electrical signals.

[0101] S4: Application and Optimization of Mathematical Model Relationships. Based on the mathematical model relationships established in S3, the relationships are transformed into key indicator information for input through the human-computer interaction function of the control terminal. Real-time comparison of electrical signals with reference values ​​is performed to monitor the concrete production process in the ready-mixed concrete plant, and optimization is carried out based on the application. Specifically:

[0102] The mathematical model relationship is transformed into key indicator information input by comparing real-time electrical signals and key indicator information. The comparison method involves establishing a relationship between the real-time electrical signals and key indicator information. This relationship includes constants, formulas, and variables, established through comparisons, range calculations, and proportions, thereby achieving monitoring of the production process. A specific example is as follows:

[0103] Based on the slump data measured at the benchmark point, and considering factors such as production line, strength grade, and volume, the following relationship model between slump and electrical signal (the difference between peak current and no-load current) was obtained: Figure 3 As shown, the relationship conforms to a cubic polynomial (the bold dashed line in the figure, correlation coefficient R2 = 0.9915).

[0104] Mathematical analysis of the relational model: Let the slump be L, the difference between the peak current and the no-load current be A, and the production reference value be set as L∈[180,200]. Then, according to the mathematical model, A should be ∈[73,82], and [73,82] is the reference value. The corresponding relation is established as: 73≤A≤82. (Refer to...) Figure 4 The system inputs reference values ​​through the control host and control terminal, and applies them to the monitoring of the corresponding production line and strength level range and volume production process. The reference values ​​are usable and acceptable values ​​based on the established mathematical model. The reference values ​​are affected by different production process characteristics, and the same key indicator will vary in different production lines, strength levels, and other production processes.

[0105] In this embodiment, by adding an electrical signal acquisition device, especially using a current transformer, there is no need to connect to the existing circuit. The required hardware is simple, installation is easy, and installation time is short. Wireless and wired connections are flexible and controllable, offering advantages such as controllable modification costs, low construction difficulty, and minimal impact on production. By collecting and organizing test data and establishing mathematical relationship models by production line and strength grade, the failure of mathematical relationship models caused by equipment differences and concrete characteristics can be eliminated, improving the accuracy of the monitoring method. Furthermore, through various key indicator information, real-time monitoring of equipment status, mixing process, working performance, energy consumption, and energy efficiency can be achieved, providing a wide monitoring range. Through the control host and terminal, automatic identification, recording, and early warning of abnormal situations can be realized, demonstrating a high degree of automation and intelligence. By linking production information, working performance information, and electrical signal information, orderly data accumulation can be achieved, aiding in the tracing of production process problems and contributing to stable production quality and management.

[0106] Reference Figure 5 This invention also provides a monitoring system for the concrete production process of a ready-mixed plant. This system includes a data acquisition unit 100, an information acquisition unit 200, a model building unit 300, a relationship building unit 400, and a production monitoring unit 500, wherein:

[0107] The data acquisition unit 100 is used to acquire electrical signals, temperature and humidity information, and production information from multiple ready-mixed concrete production lines.

[0108] The information acquisition unit 200 is used to send electrical signals, temperature and humidity information and production information to the control host, so that the reference test point controls the temperature and humidity of the environment according to the temperature and humidity information, and measures the working performance index information corresponding to the electrical signals and production information.

[0109] Model building unit 300 is used to establish the mathematical model relationship corresponding to each ready-mixed concrete production line based on electrical signals, production information and work performance index information.

[0110] The relation establishment unit 400 is used to transform mathematical model relations into key indicator information and establish the relational expression between the real-time electrical signals and key indicator information corresponding to the key indicator information.

[0111] The production monitoring unit 500 is used to input the reference values ​​corresponding to key indicator information to the control terminal and monitor the concrete production process of the ready-mixed plant according to the relationship between real-time electrical signals and key indicator information.

[0112] It should be noted that since the ready-mixed concrete production process monitoring system in this embodiment is based on the same inventive concept as the ready-mixed concrete production process monitoring method described above, the corresponding content in the method embodiment is also applicable to this system embodiment, and will not be described in detail here.

[0113] Reference Figure 6 This application also provides a monitoring device for the concrete production process of a ready-mixed plant, which includes:

[0114] At least one memory;

[0115] At least one processor;

[0116] At least one program;

[0117] The program is stored in memory, and the processor executes at least one program to implement the above-described method for monitoring the concrete production process in a ready-mixed plant.

[0118] This electronic device can be any smart terminal, including mobile phones, tablets, personal digital assistants (PDAs), and in-vehicle computers.

[0119] The electronic devices according to embodiments of this application will now be described in detail.

[0120] The processor 1600 can be implemented using a general-purpose central processing unit (CPU), microprocessor, application-specific integrated circuit (ASIC), or one or more integrated circuits, and is used to execute relevant programs to implement the technical solutions provided in the embodiments of this disclosure.

[0121] The memory 1700 can be implemented as a read-only memory (ROM), static storage device, dynamic storage device, or random access memory (RAM). The memory 1700 can store the operating system and other application programs. When the technical solutions provided in the embodiments of this specification are implemented through software or firmware, the relevant program code is stored in the memory 1700 and is called and executed by the processor 1600 to execute the ready-mixed concrete production process monitoring method of the embodiments of this disclosure.

[0122] The input / output interface 1800 is used to implement information input and output.

[0123] The communication interface 1900 is used to enable communication and interaction between this device and other devices. Communication can be achieved through wired means (such as USB, Ethernet cable, etc.) or wireless means (such as mobile network, WIFI, Bluetooth, etc.).

[0124] Bus 2000 transmits information between various components of the device (e.g., processor 1600, memory 1700, input / output interface 1800, and communication interface 1900);

[0125] The processor 1600, memory 1700, input / output interface 1800 and communication interface 1900 are connected to each other within the device via bus 2000.

[0126] This disclosure also provides a storage medium, which is a computer-readable storage medium storing computer-executable instructions for causing a computer to execute the above-described method for monitoring the concrete production process in a ready-mixed plant.

[0127] Memory, as a non-transitory computer-readable storage medium, can be used to store non-transitory software programs and non-transitory computer-executable programs. Furthermore, memory may include high-speed random access memory, and may also include non-transitory memory, such as at least one disk storage device, flash memory device, or other non-transitory solid-state storage device. In some embodiments, memory may optionally include memory remotely located relative to the processor, and these remote memories can be connected to the processor via a network. Examples of such networks include, but are not limited to, the Internet, intranets, local area networks, mobile communication networks, and combinations thereof.

[0128] The embodiments described in this disclosure are for the purpose of more clearly illustrating the technical solutions of this disclosure and do not constitute a limitation on the technical solutions provided by this disclosure. As those skilled in the art will know, with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by this disclosure are also applicable to similar technical problems.

[0129] Those skilled in the art will understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of this disclosure, and may include more or fewer steps than shown, or combine certain steps, or different steps.

[0130] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0131] Those skilled in the art will understand that all or some of the steps in the methods disclosed above, as well as the functional modules / units in the systems and devices, can be implemented as software, firmware, hardware, or suitable combinations thereof.

[0132] The terms “first,” “second,” “third,” “fourth,” etc. (if present) in the specification and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms “comprising” and “having,” and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0133] It should be understood that in this application, "at least one (item)" means one or more, and "more than" means two or more. "And / or" is used to describe the relationship between related objects, indicating that three relationships can exist. For example, "A and / or B" can represent three cases: only A exists, only B exists, and both A and B exist simultaneously, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "At least one (item) of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one (item) of a, b, or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, and c can be single or multiple.

[0134] In the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between apparatuses or units may be electrical, mechanical, or other forms.

[0135] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0136] Furthermore, the functional units in the various embodiments of this application can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0137] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes multiple instructions to cause an electronic device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this application. The aforementioned storage medium includes various media capable of storing programs, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks. The embodiments of this application have been described in detail above with reference to the accompanying drawings, but this application is not limited to the above embodiments. Various changes can be made within the scope of knowledge possessed by those skilled in the art without departing from the spirit of this application.

Claims

1. A method for monitoring the concrete production process in a ready-mixed concrete plant, characterized in that, The monitoring methods for the concrete production process at the ready-mixed plant include: Acquire electrical signals, temperature and humidity information, and production information from multiple ready-mixed concrete production lines; The electrical signal, the temperature and humidity information, and the production information are sent to the control host so that the benchmark test point controls the temperature and humidity of the environment according to the temperature and humidity information, and measures the working performance index information corresponding to the electrical signal and the production information. Based on the electrical signals, the production information, and the performance index information, a mathematical model relationship is established for each of the ready-mixed concrete production lines; the performance index information includes slump, slump spread, plastic viscosity, and static yield stress. The mathematical model relationship is transformed into key indicator information, and a relationship is established between the real-time electrical signal corresponding to the key indicator information and the key indicator information; the key indicator information includes no-load current, peak current, steady current, current difference, current change rate, and voltage. The reference values ​​corresponding to the key indicator information are input to the control terminal, and the ready-mixed concrete production process of the plant is monitored according to the relationship between the real-time electrical signal and the key indicator information, including: Acquire real-time electrical signals during the concrete production process at a ready-mixed plant; The reference values ​​corresponding to the key indicator information are input to the control terminal. Based on the relationship between the real-time electrical signal and the key indicator information, the real-time electrical signal in the concrete production process of the ready-mixed plant is compared with the reference values ​​corresponding to the key indicator information to realize the monitoring of the concrete production process of the ready-mixed plant. The reference value is the numerical range, specific value or relationship of the key indicator information input through the human-computer interaction function of the control terminal.

2. The method for monitoring the concrete production process in a ready-mixed plant according to claim 1, characterized in that, The step of establishing a mathematical model relationship for each ready-mixed concrete production line based on the electrical signal, the production information, and the performance index information includes: Based on the electrical signals, the production information, and the performance indicators, a mathematical model is constructed to establish the relationship between the concrete performance, equipment status, energy consumption and efficiency, abnormal situation tracing, and electrical signals for each ready-mixed concrete production line.

3. The method for monitoring the concrete production process in a ready-mixed plant according to claim 2, characterized in that, The concrete workability includes slump, and the mathematical model relationship between the concrete workability and the electrical signal includes: Calculate the difference between the peak current and the no-load current generated during each batch of concrete mixing at the ready-mix plant; When the slump is in a first range, a second range of the difference corresponding to the slump is determined based on the first range, and a mathematical model relationship between the slump and the difference is established based on the first range and the second range.

4. The method for monitoring the concrete production process in a ready-mixed plant according to claim 2, characterized in that, The construction of the mathematical model relationship between the device state and the electrical signal includes: When the no-load current value of the mixer is greater than the first preset value, it is determined that there is an abnormality in the mixer equipment; Calculate the rate of change of current based on the current value at the previous moment and the current value at the current moment; When the absolute value of the current change rate is greater than the second preset value, it is determined that there is an abnormality in the mixing process.

5. The method for monitoring the concrete production process in a ready-mixed plant according to claim 2, characterized in that, The construction of the mathematical model relationship between the energy consumption and efficiency and the electrical signal includes: Calculate the product of current, voltage, and time, and calculate the unit energy consumption based on the product and the stirring volume; When the unit energy consumption is greater than the third preset value, it is determined that the production energy consumption and efficiency are abnormal.

6. The method for monitoring the concrete production process in a ready-mixed plant according to claim 2, characterized in that, The construction of the mathematical model relationship between the anomaly tracing and the electrical signal includes: When an abnormal situation occurs, the source of the abnormal situation is traced by comparing the electrical signal under the abnormal situation with the electrical signal of the normal operation.

7. A monitoring system for the concrete production process in a ready-mixed plant, characterized in that, The ready-mixed concrete production process monitoring system, which applies the ready-mixed concrete production process monitoring method according to any one of claims 1 to 6, comprises: The data acquisition unit is used to acquire electrical signals, temperature and humidity information, and production information from multiple ready-mixed concrete production lines. The information acquisition unit is used to send the electrical signal, the temperature and humidity information and the production information to the control host, so that the reference test point controls the temperature and humidity of the environment according to the temperature and humidity information, and measures the working performance index information corresponding to the electrical signal and the production information. The model building unit is used to establish the mathematical model relationship corresponding to each of the ready-mixed concrete production lines based on the electrical signal, the production information and the working performance index information. The relationship establishment unit is used to convert the mathematical model relationship into key indicator information and establish the relationship between the real-time electrical signal corresponding to the key indicator information and the key indicator information. The production monitoring unit is used to input the reference values ​​corresponding to the key indicator information to the control terminal, and to monitor the concrete production process of the ready-mixed plant according to the relationship between the real-time electrical signal and the key indicator information.

8. A monitoring device for the concrete production process in a ready-mixed plant, characterized in that, It includes at least one control processor and a memory for communicatively connecting to the at least one control processor; the memory stores instructions executable by the at least one control processor, which, when executed by the at least one control processor, enable the at least one control processor to perform the ready-mixed concrete production process monitoring method as described in any one of claims 1 to 6.

9. A computer-readable storage medium, characterized in that, The computer-readable storage medium stores computer-executable instructions for causing a computer to perform the ready-mixed concrete production process monitoring method as described in any one of claims 1 to 6.

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