An intelligent control system for pouring concrete precast panel production line

Abstract

The present invention belongs to the technical field of concrete pouring control, and specifically relates to an intelligent control system for pouring concrete precast panel production line, comprising a vibration-related equipment setting module, a vibration position layout module, an initial monitoring module, an initial vibration sequence determination module, a vibration parameter setting module, a vibration sequence dynamic adjustment module, a vibration effect evaluation module and a vibration feedback module. The present invention monitors the vibration state and vibration effect of vibrated concrete casting bodies in real time when using a production line to mass produce concrete precast panels, and provides feedback support for unvibrated concrete casting bodies, thereby forming a feedback closed-loop control between front and rear concrete casting bodies in mass production of concrete precast panels, making the adjustment of vibration parameters more efficient, and improving the overall turnover speed of the production line to a certain extent. At the same time, the working time and intensity of the vibration equipment are effectively controlled, which is conducive to reducing production energy consumption costs.

Description

Technical Field

[0001] The invention belongs to the technical field of concrete pouring control, and in particular relates to an intelligent control system for pouring a concrete precast slab production line. Background Art

[0002] Concrete precast panels are increasingly used in the modern construction industry due to their advantages such as fast construction speed, high cost-effectiveness and controllable quality. The resulting production demand is also increasing. In order to meet the growing production demand, the current production of concrete precast panels mostly adopts a batch production line method to maximize production efficiency.

[0003] The production of precast concrete panels mainly involves several processes, including raw material mixing, mold casting, vibration, and demoulding. Although the Chinese invention patent with application number 201910927909.4 in the prior art discloses a control system and control method for a precast concrete bridge deck production line, a control subsystem of a distribution machine, an array vibrator, a roller coating machine, a mixer and other response equipment is arranged in the production line, and an event trigger mechanism is adopted in the production process. When the distribution machine completes the distribution process of a material belt, it sends a signal to the control center, and the control center sends a signal to the vibration control subsystem and the roller coating control subsystem according to the position of each device to start the corresponding equipment. At the same time, the concrete conveying system controls the mixture conveyor to run between the distribution vibration system and the mixer to convey concrete. Therefore, the subsystem is controlled in an orderly manner to ensure that each device can be linked to achieve the continuity of the production process, and has strong adaptability, which is convenient for independent operation and control of a single subsystem.

[0004] Vibration is a crucial link in the above production. Vibration can effectively expel the bubbles inside the concrete and improve the density of the concrete. It can be said that the vibration result directly determines the production quality of the precast concrete panels. However, the above scheme only focuses on the feedback control of the related equipment before and after the vibration operation during the implementation of the vibration, and ignores the feedback control between the front and rear concrete castings in the batch production of precast concrete panels. As a result, each concrete casting is regarded as an independent object for control during the vibration process, which leads to the vibration parameters of each casting (such as vibration amplitude, vibration frequency, vibration sequence, etc.) cannot be adjusted and set according to the state of the previous casting, and a closed-loop control cannot be formed, which limits the improvement of the production efficiency of precast concrete panels. Summary of the invention

[0005] In view of this, the present invention aims to propose an intelligent control system for casting of a precast concrete slab production line, which can solve the shortcomings of the prior art that over-focuses on feedback control of related equipment before and after the vibration operation by focusing on the vibration state and vibration effect monitoring of the front and rear concrete casting bodies when using the production line to mass produce precast concrete slabs.

[0006] The purpose of the present invention can be achieved through the following technical solutions: A concrete precast slab production line casting intelligent control system, comprising the following modules: a vibration-related equipment setting module, used to set a vibration terminal, a visual monitoring terminal and an environmental collection terminal in the vibration area of ​​the concrete precast slab production line.

[0007] The vibration position layout module is used to layout the vibration position according to the shape of the current batch of concrete precast slab molds.

[0008] The initial monitoring module is used to control the production line to stop conveying after the casting body is formed after the concrete precast slab is poured and transferred to the vibration area through the production line. The visual monitoring terminal scans the surface of the current casting body to form a scanning image, and then extracts the initial concrete state characteristics of each vibration position in the casting body. At the same time, the temperature of the vibration area is collected by the environment collection terminal.

[0009] The initial vibration sequence determination module is used to determine the initial implementation sequence of the vibration positions corresponding to the current cast unit based on the initial concrete state characteristics of each vibration position in the cast unit.

[0010] The vibration parameter setting module is used to set the vibration parameters based on the initial concrete state characteristics corresponding to each vibration position in the initial implementation sequence of the vibration position and the temperature of the vibration area.

[0011] The module for dynamically adjusting the vibration sequence is used to implement the initial implementation sequence of the vibration position corresponding to the current cast body and the vibration parameters of the corresponding vibration position by the vibration terminal and then re-use the visual monitoring terminal to scan, thereby dynamically adjusting the initial vibration sequence.

[0012] The vibration effect evaluation module is used to record the vibration implementation data and vibration evaluation indicators after the vibration of each cast body is completed, and to evaluate the vibration effect based on the vibration evaluation indicators.

[0013] The vibration feedback module is used to select the associated cast unit before vibrating the next cast unit by combining the visual scanning result of the next cast unit and the vibration effect of the vibrated cast unit, and then set the vibration feedback for the next cast unit based on the vibration implementation data of the associated cast unit.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. When the present invention utilizes a production line to mass-produce concrete precast panels, the vibration state and vibration effect of the vibrated concrete castings are monitored in real time, and feedback support is provided for the unvibrated concrete castings, thereby forming a feedback closed-loop control between the front and rear concrete castings in the mass production of concrete precast panels, making the adjustment of vibration parameters more efficient, reducing the debugging time and the need for human intervention, and improving the overall turnover speed of the production line to a certain extent. At the same time, the working time and intensity of the vibration equipment are effectively controlled, which is conducive to reducing production energy consumption costs.

[0015] 2. The present invention takes into account that a concrete casting needs to be vibrated at multiple positions during the vibration operation. Therefore, the concrete state characteristics of different vibration positions are obtained by visually scanning the casting before vibration, and then the different vibration positions are initially sorted and arranged accordingly, so that targeted vibration can be carried out to ensure that the problem positions are vibrated first, thereby improving the overall vibration efficiency.

[0016] 3. The present invention performs scanning and monitoring of unvibrated positions after each vibrated position is completed while vibrating according to the initial implementation sequence of the concrete casting vibration positions, and dynamically adjusts the initial implementation sequence based on the scanning and monitoring results in combination with the proximity principle, which can reflect the dynamic optimization and adjustment of the vibration operation, improve production flexibility and adaptability, and help to ensure the continuous improvement of the vibration efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for describing the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative work.

[0018] Figure 1 It is a schematic diagram of the connection of each module of the system of the present invention.

[0019] Figure 2 It is a schematic diagram of the setting of vibration-related equipment on the concrete precast panel production line of the present invention.

[0020] Figure 3 It is a schematic diagram of the layout of vibration positions of a rectangular concrete precast panel mold in the present invention.

[0021] Figure numerals: 1 - casting body, 2 - vibration area, 3 - vibration terminal, 4 - visual monitoring terminal, 5 - environment collection terminal. DETAILED DESCRIPTION

[0022] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0023] The present invention proposes an intelligent control system for pouring a concrete precast slab production line, comprising a vibration-related equipment setting module, a vibration position layout module, an initial monitoring module, an initial vibration sequence determination module, a vibration parameter setting module, a vibration sequence dynamic adjustment module, a vibration effect evaluation module and a vibration feedback module.

[0024] See also Figure 1 As shown, the above-mentioned vibration-related equipment setting module and the vibration position layout module are both connected to the initial monitoring module, the initial monitoring module is connected to the initial vibration sequence determination module, the initial vibration sequence determination module is respectively connected to the vibration parameter setting module and the vibration sequence dynamic adjustment module, the vibration sequence dynamic adjustment module is connected to the vibration effect evaluation module, and the vibration effect evaluation module is connected to the vibration feedback module.

[0025] The vibration-related equipment setting module is used to set a vibration terminal, a visual monitoring terminal and an environment collection terminal in the vibration area of ​​the concrete precast panel production line. Figure 2 shown.

[0026] In the specific implementation of the above scheme, the vibration terminal is an inserted vibration rod, which is usually composed of a motor, a flexible shaft and a vibration head. In the specific vibration operation, the vibration rod is inserted into the concrete, and vibration is generated by high-speed rotation to make the concrete dense.

[0027] In another specific implementation of the above scheme, the visual monitoring terminal is a high-definition camera, which is usually arranged above the vibration area and is used to scan the cast body transported to the vibration area to form a scanned image.

[0028] In another specific implementation of the above solution, the environment collection terminal is a temperature sensor for collecting the temperature of the vibration area.

[0029] The vibration position layout module is used to layout the vibration position of the casting body according to the size and shape of the current batch of concrete precast slab molds. Figure 3 shown.

[0030] In a specific example, assuming that the shape of the concrete precast panel mold is a rectangle, the mold can be divided into uniform grids, wherein the spacing between grids is generally about 1.5 times the diameter of the vibrating rod, and the center point of each grid is taken as the vibration position.

[0031] In another specific example, assuming that the shape of the concrete precast panel mold is circular, a vibration position can be arranged at the center of the mold, thereby dividing the mold into multiple concentric rings. The diameter of each ring is still about 1.5 times the diameter of the vibrating rod, and the vibration positions are evenly arranged along the circumferential direction in each ring.

[0032] It needs to be understood that in forming the cast body, it is usually necessary to arrange multiple vibration positions, but there is a single vibration position. This is because the vibration energy of the vibration equipment at a single vibration position may not be sufficient to cover the entire cast body, resulting in insufficient vibration in areas far away from the vibration point, thus causing problems such as voids and bubbles. By arranging multiple vibration positions in the cast body, it can be ensured that the vibration energy is evenly distributed in the entire cast body, making the concrete more compact.

[0033] It is further understood that when arranging multiple vibration positions in the cast body, they should be arranged in a targeted manner according to the shape of the precast panel mold because the shape of the mold determines the distribution of concrete in different areas.

[0034] In the example understood above, the concrete distribution characteristics of the rectangular mold are: the concrete distribution in the center area is relatively uniform, because it is far away from the edge of the mold and is less subject to external constraints; the concrete distribution in the corner area may be uneven, especially during the pouring process, the concrete is prone to accumulation or bubble formation. The concrete distribution characteristics of the circular mold are: the concrete distribution in the center area is relatively uniform, but there are no obvious corner areas. It can be seen that the rectangular mold needs to pay special attention to the corner areas, and the grid division is performed in the mold to ensure that the corner areas can also be vibrated. The circular mold does not need to pay attention to the corner areas. If a unified layout method is used, it may not be able to fully consider the specific needs of molds of different shapes, resulting in insufficient vibration, bubbles and voids, uneven surfaces and other problems, thereby affecting the quality of the precast panels.

[0035] The initial monitoring module is used to control the production line to stop conveying after the casting body is formed after the concrete precast slab is cast and is transferred to the vibration area through the production line. The visual monitoring terminal scans the surface of the current casting body to form a scanning image, and then extracts the initial concrete state characteristics of each vibration position in the casting body. At the same time, the environment collection terminal is used to collect the temperature of the vibration area.

[0036] In a preferred example implementation of the above scheme, the specific execution of controlling the production line to stop conveying after the cast body is transferred to the vibration area through the production line can be to install a proximity sensor and a photoelectric sensor before the production line enters the vibration area. When the proximity sensor detects the cast body, the control system starts to calculate the position. When the photoelectric sensor detects that the cast body enters the vibration area, the production line control center determines whether the stop conditions are met. If the stop conditions are met, the control system sends a deceleration and stop command to the motor, thereby stopping the production line.

[0037] It should be further added that, after all vibration positions of the current cast body have completed vibration, the production line control center sends a start command to the motor and the production line restarts.

[0038] It needs to be explained that the purpose of controlling the production line to stop conveying after the cast unit is transferred to the vibration area through the production line is to ensure that the visual monitoring terminal scans under stable conditions to obtain clear and accurate images, which helps to accurately identify the concrete state characteristics on the surface of the cast unit.

[0039] As a preferred implementation of the above scheme, the initial concrete state characteristics of each vibration position in the cast body are extracted as follows: the scanned image is divided into a number of regional images according to the arranged vibration positions, wherein each regional image corresponds to a vibration position, and specifically, the center point of each regional image is the arranged vibration position.

[0040] Concrete texture features, concrete color features and concrete apparent defect features are extracted from each region image as initial concrete state features of each vibration position, wherein the concrete apparent defect features include the apparent defect type, the number of apparent defects and the apparent defect area. Exemplarily, the concrete apparent defect features include but are not limited to bubbles, cracks, honeycombs, etc.

[0041] It is important to know that the concrete texture features reflect the roughness of concrete pouring, the concrete color features reflect the uniformity of concrete pouring, and the concrete surface defect features reflect the defects of concrete pouring. The features reflecting the roughness, uniformity and defects of concrete pouring are extracted from the scanned images as concrete state features because these features all affect the density of concrete. By extracting these features, the vibration requirements of concrete can be comprehensively evaluated, providing accurate guidance for subsequent vibration operations.

[0042] It should be added that when performing initial concrete state feature extraction on the scanned image, it is necessary to perform preprocessing operations such as image enhancement, denoising, and background segmentation on the scanned image, which can significantly improve the accuracy and reliability of subsequent feature extraction.

[0043] The initial vibration sequence determination module is used to determine the initial implementation sequence of the vibration positions corresponding to the current cast body based on the initial concrete state characteristics of each vibration position in the cast body. The detailed process is as follows: a grayscale co-occurrence matrix is ​​constructed based on the concrete texture characteristics of each vibration position, wherein the grayscale co-occurrence matrix is ​​a statistical method used to describe the spatial distribution of the grayscale relationship between pixels in an image, thereby analyzing the surface roughness of the concrete. In the specific implementation, the grayscale co-occurrence matrix construction process belongs to the prior art and will not be described here.

[0044] After the construction is completed, the contrast, homogeneity, energy, entropy and other parameters are extracted from it. Among them, the contrast describes the local variation of the gray value and indicates the clarity of the image; the homogeneity describes the similarity of the gray value and indicates the uniformity of the image; the energy describes the consistency of the gray value and indicates the smoothness of the image; the entropy describes the uncertainty of the gray value and indicates the complexity of the image. These parameters are dimensionless parameters. The higher the contrast, the more gray changes there are on the concrete surface and the surface is rough. The lower the homogeneity, the uneven distribution of the gray value on the concrete surface and the rough surface. The lower the energy, the inconsistent distribution of the gray value on the concrete surface and the rough surface. The higher the entropy, the complex distribution of the gray value on the concrete surface and the rough surface. Based on this, the weight value of the parameter can be determined in combination with the direction of the influence of these parameters on the roughness, and the weighted average calculation is performed to obtain the surface roughness of the concrete.

[0045] A color histogram of each vibration position is constructed based on the concrete color features at each vibration position, where a color histogram is a histogram that statistically analyzes the distribution of each color in the image and displays it graphically. The brightness or intensity distribution of each color channel is shown in the figure, usually as three separate histograms (one for red, one for green, and one for blue), thereby calculating the variance of the concrete color distribution at each vibration position.

[0046] In a preferred implementation of the above solution, the calculation of the variance of the concrete color distribution can be obtained by performing a variance operation on the brightness or intensity of each color channel.

[0047] The apparent defect types are extracted from the apparent defect characteristics of the concrete and converted into influence degrees. Thus, the apparent defect areas corresponding to the apparent defects of the same apparent defect type in the apparent defect characteristics of the concrete at each vibration position are accumulated to obtain the cumulative area of ​​each apparent defect type. The cumulative area of ​​each apparent defect type is then divided by the scanned image area and multiplied by the corresponding influence degree of the corresponding apparent defect type to obtain the apparent defect degree of the concrete at each vibration position.

[0048] As an example implementation, when converting the degree of influence of the performance defect type, the influence of different performance defect types on the quality of the concrete precast slab can be considered empirically for conversion setting. For example, bubbles are usually caused by insufficient distribution of concrete or trapped air. The presence of small bubbles may cause the compactness of concrete to decrease, but the impact on the overall structural strength is usually small, so the influence of bubbles is small, while cracks directly affect the structural integrity of concrete, especially wider and deeper cracks. Cracks may cause the strength and durability of concrete to decrease, and even affect the safety of the structure. Therefore, the influence of cracks is greater than that of bubbles. Honeycombs are voids or discontinuous areas in concrete, usually caused by uneven aggregation of aggregates, which may cause the compactness and strength of concrete to decrease, increasing the fragility of the structure, but cracks usually have a more direct impact on the structural integrity and long-term durability of concrete. It can be seen that the influence of honeycombs is smaller than that of cracks but larger than that of bubbles. Based on this, the magnitude relationship of the influence of the performance defect types can be obtained as bubbles < honeycombs < cracks. By setting the interval from 0 to 1 as the range of the degree of influence, the influence of bubbles can be 0.2, the influence of honeycombs is 0.6, and the influence of cracks is 0.9.

[0049] Arrange the vibration positions in descending order according to the surface roughness of concrete, the variance of concrete color distribution and the apparent defect degree of concrete, and obtain the first arrangement result, the second arrangement result and the third arrangement result of the vibration positions, and record the ranking number of each vibration position in the corresponding arrangement result respectively.

[0050] It should be understood that the smaller the ranking number in the above arrangement results, the more priority is given to vibration.

[0051] The ranking numbers of each vibration position in the corresponding arrangement result are accumulated and then the inverse is taken to obtain the priority of each vibration position, and then the initial implementation order of the vibration positions corresponding to the current cast body is obtained by arranging them in descending order of priority.

[0052] The vibration parameter setting module is used to set the vibration parameters based on the initial concrete state characteristics corresponding to each vibration position in the initial implementation sequence of the vibration position and the temperature of the vibration area. The specific settings are as follows: the temperature of the vibration area is compared with the appropriate vibration temperature range to calculate the vibration temperature deviation, and the temperature deviation direction is identified, where the temperature deviation direction includes upward deviation and downward deviation.

[0053] The above-mentioned suitable vibration temperature range is mainly determined by the ratio of concrete raw materials. Exemplarily, the suitable vibration temperature range is 10°C to 30°C.

[0054] Furthermore, the vibration temperature deviation is calculated as follows: comparing the temperature of the vibration area with the suitable vibration temperature range; if the temperature of the vibration area falls within the suitable vibration temperature range, the vibration temperature deviation is 0, and there is no temperature deviation direction; if the temperature of the vibration area does not fall within the suitable vibration temperature range, then comparing the temperature of the vibration area with the upper limit temperature and the lower limit temperature of the suitable vibration temperature range; if the temperature of the vibration area is higher than the upper limit temperature, the temperature deviation direction is an upward deviation, and the vibration temperature deviation is specifically calculated as the difference between the temperature of the vibration area and the upper limit temperature divided by the upper limit temperature; if the temperature of the vibration area is lower than the lower limit temperature, the temperature deviation direction is a downward deviation, and the vibration temperature deviation is specifically calculated as the difference between the lower limit temperature and the temperature of the vibration area divided by the lower limit temperature.

[0055] It should be added that temperature is selected as the environmental parameter in the vibration area because temperature directly affects the fluidity, solidification time and ultimate strength of concrete. When the temperature is not suitable, high temperature will accelerate the initial setting of concrete, reduce its fluidity, and make it difficult to achieve a uniform and dense effect during vibration; low temperature may cause the concrete to thicken and increase the difficulty of vibration. Therefore, temperature has the greatest impact on the vibration operation.

[0056] The initial concrete state characteristics at each vibration position are compared with the state characteristics of the qualified concrete, and the required vibration intensity at each vibration position is calculated.

[0057] The above-mentioned state characteristics of qualified concrete are also determined by the proportion of concrete raw materials.

[0058] It can be understood that the initial concrete state characteristics of each vibration position are converted into the state characteristics of the standard concrete through vibration. The difference between them is the required vibration intensity. In the specific operation, the required vibration intensity of each vibration position can be obtained by subtracting the initial concrete state characteristics of each vibration position from the state characteristics of the standard concrete, dividing by the state characteristics of the standard concrete, and then dividing by 3. The specific calculation formula is: , where , , They represent the initial concrete surface roughness, concrete color distribution variance and concrete apparent defect degree at each vibration position, , , They respectively represent the surface roughness of qualified concrete, the color distribution variance of qualified concrete, and the apparent defect degree of qualified concrete.

[0059] An edge detection algorithm is used to identify the edge area of ​​the casting body from the surface scan image of the current casting body, and then a contour extraction algorithm is used to extract the closed edge line of the mold surface from the edge area.

[0060] The vibration position and center point are marked in the surface scanning image of the current cast body, and then a perpendicular line is drawn from the vibration position and center point to the edge closing line of the mold surface to obtain the distance from the vibration position and center point to the edge closing line of the mold surface, which are recorded as the edge distance and the center-edge distance respectively.

[0061] The edge distance of each vibration position Distance from center edge Compare and calculate the edge proximity of each vibration position. The specific calculation formula is: From this formula, we can know that the center-edge distance is the farthest distance from the mold surface edge closing line among all vibration positions. When the difference between the edge distance of each vibration position and the center-edge distance is larger, it means that the vibration position falls on the mold surface edge closing line, and the edge proximity is greater.

[0062] The vibration intensity required and edge proximity of each vibration position are combined with the vibration environment deviation and temperature deviation direction to introduce the formula , and obtain the optimized vibration intensity required for each vibration position , , , They represent the vibration intensity, edge proximity, and vibration temperature deviation of the vibration position. Indicates the direction of temperature deviation.

[0063] It should be understood that when setting the vibration parameters of the vibration position, it is necessary to consider not only the required vibration intensity, but also whether the vibration position falls on the edge and the impact of the environment on the vibration. When the vibration position falls on the edge, the vibration generated during vibration may produce excessive pressure on the mold, which may cause mold deformation or concrete leakage. Therefore, the closer to the edge, the lower the required vibration intensity needs to be. The higher the temperature, that is, the temperature deviates upward, the shorter the setting time of the concrete, and the vibration frequency may need to be increased to avoid bubbles being trapped in the concrete. The lower the temperature, that is, the temperature deviates downward, the slower the concrete sets, and the vibration frequency may need to be reduced to avoid excessive vibration. It can be seen that in actual vibration, it is necessary to combine the edge proximity of the vibration position and the temperature deviation, that is, the temperature deviation direction, to adapt the vibration intensity required to enhance the rationality of the vibration parameter setting.

[0064] A correspondence between the required vibration intensity and the vibration parameters is constructed, thereby extracting the vibration parameters corresponding to each vibration position from the correspondence between the required vibration intensity and the vibration parameters based on the optimized required vibration intensity of each vibration position, and setting them.

[0065] In the optimized implementation of the above scheme, experimental pouring can be performed to construct the correspondence between the required vibration intensity and the vibration parameters. By adjusting different vibration parameters, collecting data on different vibration parameters and actual vibration results, and establishing a mathematical model between vibration parameters and required vibration intensity, the correspondence between the required vibration intensity and the vibration parameters can be obtained.

[0066] In the example implementation of the above solution, the vibration parameters may be vibration frequency and vibration amplitude.

[0067] The vibration sequence dynamic adjustment module is used to reuse the visual monitoring terminal to scan after the vibration terminal implements the vibration according to the initial implementation order of the vibration position corresponding to the current cast body and the vibration parameters of the corresponding vibration position, thereby dynamically adjusting the initial vibration sequence. The process is as follows: after the vibration operation at each vibration position is completed, the vibration position where the vibration operation is completed is remembered as the vibrated position, and the other vibration positions are remembered as the unvibrated positions, and then the visual monitoring terminal is reused to scan the surface of the current cast body to form a scanned image, from which the concrete state characteristics of the unvibrated position in the cast body are extracted.

[0068] Similarly, the concrete state characteristics of the unvibrated positions are arranged in the first, second and third order to obtain the priority of the unvibrated positions.

[0069] The unvibrated position is compared with the vibrated position to obtain the distance between the unvibrated position and the vibrated position.

[0070] The distance between the unvibrated position and the vibrated position is combined with the priority of the unvibrated position using the expression Get additional priority for unvibrated positions , Indicates the priority of the unvibrated position in the initial implementation sequence of the vibrated position. Indicates the distance between the unvibrated position and the vibrated position. Represents the sum of the distances between all unvibrated locations and the vibrated locations.

[0071] Arrange the unvibrated positions in descending order of additional priority to obtain the current demand implementation order of the unvibrated positions.

[0072] For example, suppose that on a cast unit, the initial implementation order of the vibration positions is A→B→C→D. After vibrating position A, scanning monitoring is performed and it is found that there is a bubble problem at position B, and position C is close to position A and also has a bubble problem. At this time, according to the dynamic adjustment principle, the next vibration position can be adjusted to position C, and then position B can be processed. This can reduce the moving distance of the vibration tool and give priority to the problem area.

[0073] The present invention not only takes the concrete state characteristics of the un-vibrated position as the main adjustment basis when dynamically adjusting the implementation order of the vibration positions during the vibration process, but also introduces the proximity principle, which can reduce the moving distance of the vibration tool in the working area while maximally satisfying the vibration according to the priority, reduce the operation time, and improve the overall construction efficiency.

[0074] Compare the initial implementation sequence of the unvibrated positions with the current required implementation sequence. If there is any inconsistency, adjust the initial implementation sequence according to the current required implementation sequence.

[0075] The vibration effect evaluation module is used to record the vibration implementation data and vibration evaluation indicators after the vibration of each casting body is completed, wherein the vibration implementation data includes the initial implementation order of the vibration position and the vibration parameters set at each vibration position, the vibration evaluation indicators include the vibration duration and the concrete state characteristics of each vibration position after the vibration is completed, and the vibration effect is evaluated according to the vibration evaluation indicators. The specific evaluation process is: the concrete state characteristics of each vibration position in the vibrated casting body are compared with the concrete state characteristics that meet the standards to calculate the vibration compliance of the vibrated casting body. The specific calculation can be based on two-fifths as the base, and the difference between the concrete state characteristics of each vibration position and the concrete state characteristics that meet the standards is divided by the result of the concrete state characteristics that meet the standards as an exponent to construct an exponential function to obtain the vibration compliance of each vibration position, and then the minimum vibration compliance is taken as the vibration compliance of the vibrated casting body. From this formula, it can be seen that the closer the concrete state characteristics of each vibration position are to the concrete state characteristics that meet the standards, the greater the vibration compliance.

[0076] After dividing the vibration time of the vibrated cast body by the reference time, an exponential function is constructed with three-fifths as the base and the division result as the exponent to obtain the vibration time effectiveness of the vibrated cast body, wherein the shorter the vibration time of the vibrated cast body, the greater the vibration time effectiveness and the higher the vibration efficiency. The reference time is used to eliminate dimensions in the calculation of vibration time effectiveness. Exemplarily, the reference time may be the average vibration time of the cast body corresponding to the same concrete precast slab mold and the same raw material ratio in the historical vibration records.

[0077] The vibration effect coefficient of the vibrated cast body is obtained by adding the vibration standard degree and the vibration time effectiveness degree of the vibrated cast body.

[0078] The associated cast unit screening module is used to screen out the associated cast units before vibrating the next cast unit by combining the visual scanning result of the cast unit and the vibration effect of the vibrated cast unit. The screening process is as follows: extract the initial concrete state characteristics corresponding to each vibration position from the visual scanning result of the next cast unit and compare them with the initial concrete state characteristics of the vibrated cast unit at each vibration position. The specific similarity comparison is: subtract the initial concrete state characteristics corresponding to the same vibration position and divide the absolute value of the difference result by the initial concrete state characteristics of the corresponding vibration position in the vibrated cast unit. State characteristics, obtain the concrete state deviation corresponding to each vibration position, and then extract the maximum deviation therefrom, and take the difference between 1 and the maximum deviation as a percentage to obtain the concrete state similarity between the next cast unit and the vibrated cast unit, wherein the larger the deviation, the smaller the similarity, and select the reference cast unit therefrom, specifically by comparing the concrete state similarity between the next cast unit and the vibrated cast unit with the similarity threshold set by the system, illustratively, the similarity threshold is 90%, and extract the vibrated cast unit that reaches the similarity threshold as the reference cast unit.

[0079] The reference cast unit corresponding to the maximum vibration effect coefficient is selected from the reference cast units as the associated cast units.

[0080] The vibration feedback module is used to set the vibration of the next cast unit based on the vibration implementation data of the associated cast unit, specifically to directly use the vibration implementation data of the associated cast unit to set the vibration position implementation sequence and vibration parameters of the next cast unit.

[0081] The present invention selects associated cast units with similar concrete state characteristics and good vibration effects from the vibrated cast units based on the concrete state characteristics of the next cast unit before vibrating the next cast unit, and then directly sets the vibration position implementation sequence and vibration parameters of the associated cast units for the next cast unit, thereby realizing vibration feedback closed control of the previous and next cast units. Therefore, by drawing on the successful vibration settings, the need for a large number of tests and adjustments on the next cast unit can be reduced, and the construction progress can be accelerated. At the same time, the use of vibration data with similar concrete state characteristics can improve the consistency of the vibration process and ensure that the concrete quality of each cast unit meets the expected standards.

[0082] It should be noted that when the associated cast unit is used to perform pouring feedback control on the next cast unit, the initial implementation sequence of the vibration position is directly set. In actual operation, the implementation sequence of the vibration position of the next cast unit can be dynamically adjusted according to the vibration results.

[0083] The above contents are merely examples and explanations of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the concept of the invention or exceed the scope defined by the present invention, they shall all fall within the protection scope of the present invention.

Claims

1. An intelligent control system for pouring concrete precast panel production line, characterized in that: Includes the following modules: A vibration-related equipment setting module is used to set a vibration terminal, a visual monitoring terminal and an environmental collection terminal in the vibration area of ​​a concrete precast panel production line; A vibration position layout module is used to layout the vibration position according to the shape of the current batch of concrete precast slab molds; The initial monitoring module is used to control the production line to stop conveying after the concrete precast slab is cast and the casting body is transported to the vibrating area through the production line, and the visual monitoring terminal scans the surface of the current casting body to form a scanning image, and then extracts the initial concrete state characteristics of each vibrating position in the casting body. At the same time, the environment collection terminal is used to collect the temperature of the vibrating area; An initial vibration sequence determination module is used to determine the initial implementation sequence of the vibration positions corresponding to the current cast unit based on the initial concrete state characteristics of each vibration position in the cast unit; A vibration parameter setting module, used to set vibration parameters based on initial concrete state characteristics corresponding to each vibration position in the initial implementation sequence of the vibration position and the temperature of the vibration area; A dynamic vibration sequence adjustment module is used for the vibration terminal to implement the initial implementation sequence of the vibration position corresponding to the current cast body and the vibration parameters of the corresponding vibration position, and then re-use the visual monitoring terminal to scan after the vibration is completed, thereby dynamically adjusting the initial vibration sequence; The vibration effect evaluation module is used to record the vibration implementation data and vibration evaluation indicators after the vibration of each cast body is completed, and to evaluate the vibration effect according to the vibration evaluation indicators; A vibration feedback module is used to select the associated cast unit before vibrating the next cast unit by combining the visual scanning result of the next cast unit and the vibration effect of the vibrated cast unit, and then set the vibration feedback for the next cast unit based on the vibration implementation data of the associated cast unit; The initial concrete state characteristics of each vibrating position in the cast unit are extracted as follows: The scanned image is divided into a plurality of regional images according to the arranged vibration positions, wherein each regional image corresponds to a vibration position, and specifically, the center point of each regional image is the arranged vibration position; Concrete texture features, concrete color features and concrete apparent defect features are extracted from each region image as initial concrete state features of each vibration position, wherein the concrete apparent defect features include apparent defect type, apparent defect location number and apparent defect area; The initial implementation sequence of the vibration positions is as follows: A gray-level co-occurrence matrix is ​​constructed based on the concrete texture features at each vibration position to analyze the surface roughness of the concrete. A color histogram of each vibration position is constructed based on the concrete color characteristics of each vibration position, thereby calculating the concrete color distribution variance of each vibration position; The apparent defect type is extracted from the apparent defect characteristics of the concrete, and its influence degree is converted, thereby accumulating the apparent defect areas corresponding to the apparent defects of the same apparent defect type in the apparent defect characteristics of the concrete at each vibration position to obtain the cumulative area of ​​each apparent defect type, and then the cumulative area of ​​each apparent defect type is divided by the scanned image area and multiplied by the corresponding influence degree of the corresponding apparent defect type to obtain the concrete apparent defect degree at each vibration position; Arrange the vibration positions in descending order according to the concrete surface roughness, the concrete color distribution variance and the concrete apparent defect degree, obtain the first arrangement result, the second arrangement result and the third arrangement result of the vibration positions, and record the ranking number of each vibration position in the corresponding arrangement result respectively; The priority of each vibration position is obtained by accumulating the ranking numbers of each vibration position in the corresponding arrangement result and then taking the inverse thereof, and then the initial implementation order of the vibration positions corresponding to the current cast unit is obtained by arranging them in descending order of priority; The vibration parameters are set as follows: Compare the temperature of the vibration area with the appropriate vibration temperature range to calculate the vibration temperature deviation , and identifying the temperature deviation direction, wherein the temperature deviation direction includes upward deviation and downward deviation; Vibration temperature deviation The calculation is as follows: the temperature of the vibration area is compared with the suitable vibration temperature interval. If the temperature of the vibration area falls within the suitable vibration temperature interval, the vibration temperature deviation is 0, and there is no temperature deviation direction. If the temperature of the vibration area does not fall within the suitable vibration temperature interval, the temperature of the vibration area is compared with the upper limit temperature and the lower limit temperature of the suitable vibration temperature interval. If the temperature of the vibration area is higher than the upper limit temperature, the temperature deviation direction is upward deviation, and the vibration temperature deviation is specifically calculated as the difference between the temperature of the vibration area and the upper limit temperature divided by the upper limit temperature. If the temperature of the vibration area is lower than the lower limit temperature, the temperature deviation direction is downward deviation, and the vibration temperature deviation is specifically calculated as the difference between the lower limit temperature and the temperature of the vibration area divided by the lower limit temperature. Compare the initial concrete state characteristics of each vibration position with the state characteristics of the qualified concrete to calculate the required vibration intensity of each vibration position ; , where , , They represent the initial concrete surface roughness, concrete color distribution variance and concrete apparent defect degree at each vibration position, , , They represent the surface roughness of qualified concrete, the color distribution variance of qualified concrete, and the apparent defect degree of qualified concrete respectively; Using an edge detection algorithm to identify the edge area of ​​the casting body from the surface scan image of the current casting body, and then using a contour extraction algorithm to extract the closed edge line of the mold surface from the edge area; The vibration position and the center point are marked in the surface scanning image of the current casting body, and then a perpendicular line is drawn from the vibration position and the center point to the edge closing line of the mold surface, and the distance from the vibration position and the center point to the edge closing line of the mold surface is obtained, which are recorded as the edge distance and the center edge distance corresponding to the vibration position, respectively; The edge distance of each vibration position Distance from center edge Compare and calculate the edge proximity of each vibration position The specific calculation formula is ; The required vibration intensity of each vibration position and edge proximity Combined vibration temperature deviation and temperature deviation direction Import formula , and obtain the optimized vibration intensity required for each vibration position ; Constructing a correspondence between the required vibration intensity and the vibration parameters, thereby extracting the vibration parameters corresponding to each vibration position from the correspondence between the required vibration intensity and the vibration parameters based on the optimized required vibration intensity of each vibration position, and setting them; The selection process of the associated cast units is as follows: Extract the initial concrete state features corresponding to each vibration position from the visual scanning results of the next cast unit, and compare them with the initial concrete state features of the vibrated cast unit at each vibration position to obtain the concrete state similarity between the next cast unit and the vibrated cast unit, and select the reference cast unit from them; The reference cast unit corresponding to the maximum vibration effect coefficient is selected from the reference cast units as the associated cast units.

2. The intelligent control system for pouring a concrete precast panel production line according to claim 1, characterized in that: The temperature deviation direction is identified as follows: The temperature of the vibration area is compared with the upper and lower temperature limits in the suitable vibration temperature range. If the temperature of the vibration area is higher than the upper temperature limit, the temperature deviation direction is upward deviation, otherwise the temperature deviation direction is downward deviation.

3. The intelligent control system for pouring concrete precast panel production line according to claim 1, characterized in that: The dynamic adjustment of the initial vibration sequence is as follows: After the vibration operation at each vibration position is completed, the vibration position where the vibration operation is completed is recorded as the vibrated position, and the other vibration positions are recorded as the unvibrated positions, and then the visual monitoring terminal is used again to scan the surface of the current cast unit to form a scanned image, from which the concrete state characteristics of the unvibrated position in the cast unit are extracted; Similarly, the concrete state characteristics of the unvibrated position are arranged in the first, second, and third order to obtain the priority of the unvibrated position; Compare the unvibrated position with the vibrated position to obtain the distance between the unvibrated position and the vibrated position; The distance between the unvibrated position and the vibrated position is combined with the priority of the unvibrated position using the expression Get additional priority for unvibrated positions , Indicates the priority of the unvibrated position in the initial implementation sequence of the vibrated position. Indicates the distance between the unvibrated position and the vibrated position. It represents the sum of the distances between all unvibrated positions and vibrated positions; Arrange the unvibrated positions in descending order according to the additional priority to obtain the current demand implementation order of the unvibrated positions; Compare the initial implementation sequence of the unvibrated positions with the current required implementation sequence. If there is any inconsistency, adjust the initial implementation sequence according to the current required implementation sequence.

4. The intelligent control system for pouring concrete precast panel production line according to claim 1, characterized in that: The vibration implementation data include the initial implementation sequence of the vibration positions and the vibration parameters set at each vibration position, and the vibration evaluation indicators include the vibration duration and the concrete state characteristics at each vibration position after the vibration is completed.

5. The intelligent control system for pouring concrete precast panel production line according to claim 4, characterized in that: The vibration effect evaluation is carried out as follows: Compare the concrete state characteristics at each vibration position in the vibrated cast unit with the concrete state characteristics that meet the standards, and calculate the vibration compliance of the vibrated cast unit; After dividing the vibration time of the vibrated cast-in-place body by the reference time, an exponential function is constructed with three fifths as the base and the division result as the exponent to obtain the vibration time effectiveness of the vibrated cast-in-place body; The vibration effect coefficient of the vibrated cast body is obtained by adding the vibration standard degree and the vibration time effectiveness degree of the vibrated cast body.

6. The intelligent control system for pouring concrete precast panel production line according to claim 1, characterized in that: The reference cast units are filtered as follows: The concrete state similarity between the next cast unit and the vibrated cast unit is compared with the similarity threshold set by the system, and the vibrated cast unit that reaches the similarity threshold is extracted as the reference cast unit.

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