A method and device for intelligent concrete unloading based on real-time monitoring of current

Abstract

The present invention relates to the technical field of concrete unloading, and the present invention provides a method and device for intelligent concrete unloading based on real-time monitoring of current, the method comprising obtaining a current signal of a concrete mixing process, establishing a neural network model, monitoring the concrete mixing state, and intelligent concrete unloading. Through the above method, the present invention can continuously judge the mixing state at each moment, so as to timely determine the time point when the concrete is mixed in a uniform state, and can predict the fluidity of the concrete in a uniform mixing state, so as to timely stop mixing and control the opening of the discharge port during unloading, thereby ensuring that the concrete is discharged in a uniform state while avoiding the waste of unnecessary mixing time, improving the quality and efficiency of production, avoiding excessive unloading or blockage caused by good or poor fluidity, and making the mixing production of concrete more stable and orderly.

Description

Technical Field

[0001] The present invention relates to the technical field of concrete unloading, and in particular to an intelligent concrete unloading method and device based on real-time monitoring of electric current. Background Art

[0002] In the production process of concrete mixing plants, there are many key factors involved, including the characteristics of raw materials, production volume, concrete strength, and environmental variables. The changes in these factors make it difficult to determine the time from concrete feeding to uniform mixing, which increases the uncertainty in the production of mixing plants. Among them, the time for concrete to be mixed uniformly is a key parameter, which directly affects the time point when the discharge door is opened, and is crucial to ensuring concrete quality and improving production efficiency.

[0003] At present, operators usually rely on experience or observe the video of the mixing process to judge the time to open the discharge door. However, this method has the disadvantages of being highly subjective and relying on individual experience, which is easy to introduce errors. When the mixing time is too short, the discharge door is opened too early, resulting in the concrete not being mixed evenly, thus failing to meet the performance requirements of the project. When the mixing time is too long, the discharge door is opened too late, which not only wastes energy and time, but also reduces the production efficiency of the mixing plant and the total output of concrete. Summary of the invention

[0004] The present invention discloses a method and device for intelligent concrete unloading based on real-time monitoring of electric current, which mainly solves the problem that in the production process of a traditional concrete mixing station, it is necessary to rely on manual experience to judge the uniform state of mixing for unloading, and this method easily causes the concrete mixing to be too short or too long, resulting in uneven concrete mixing or waste of time, thus affecting production efficiency.

[0005] To achieve the above object, the technical solution of the present invention is implemented as follows:

[0006] In a first aspect, the present invention provides a method for intelligent concrete unloading based on real-time monitoring of current, comprising the following steps:

[0007] S1. Obtaining the current signal of the concrete mixing process: real-time acquisition of the mixer main shaft current signal during the concrete mixing process;

[0008] S2. Establish a neural network model: obtain the production volume, production intensity, and environmental variables of concrete, take the production volume, production intensity, environmental variables, and current signal of concrete as input, take the mixing state and fluidity of concrete as output, establish and train a concrete mixing state prediction model that associates the current signal with the concrete mixing state and a concrete fluidity prediction model that associates the current signal with the concrete fluidity, and the concrete fluidity prediction model determines whether to perform the prediction based on the output result of the concrete mixing state prediction model;

[0009] S3. Concrete mixing state monitoring: obtain the production volume, production intensity, environmental variables and current signals of concrete in the actual production process, and input them into the concrete mixing state prediction model and concrete fluidity prediction model to obtain the prediction results;

[0010] S4. Intelligent concrete unloading: Make intelligent concrete unloading decisions based on the prediction results of S3, and obtain the decision results of whether to continue mixing concrete or stop mixing and open the size of the unloading port at the same time.

[0011] In one embodiment, the collection time period of the main shaft current signal of the mixer starts when the mixer starts to feed and ends when the mixer starts to discharge.

[0012] In one embodiment, the stirring state includes uniform and non-uniform.

[0013] In one embodiment, in the step S2, when the output result of the concrete mixing state prediction model is uniform, the concrete fluidity prediction model performs the prediction of concrete fluidity; when the output result of the concrete mixing state prediction model is uneven, the concrete fluidity prediction model does not perform the prediction of concrete fluidity.

[0014] In one embodiment, the concrete fluidity includes poor fluidity, normal fluidity and good fluidity.

[0015] In one embodiment, in the step S3, the prediction result obtained is one of uneven mixing, poor fluidity of concrete in a uniform mixing state, normal fluidity, or good fluidity.

[0016] In one embodiment, the concrete mixing state prediction model and the concrete fluidity prediction model are both composed of an input layer, a first hidden layer, a second hidden layer and an output layer connected in sequence, the input layer is used to receive production volume, production intensity, environmental variables and current signals, the first hidden layer includes 16 neurons, and the second hidden layer includes 32 neurons.

[0017] In one embodiment, the intelligent unloading decision method is that when the prediction result is uneven mixing, the mixer continues to stir; when the prediction result is that the fluidity of the concrete in the uniform mixing state is poor, normal or good, the mixer stops stirring and controls the size of the discharge port to unload.

[0018] In one embodiment, when the prediction result is that the fluidity of the concrete in the uniformly mixed state is poor, the discharge port is fully opened; when the prediction result is that the fluidity of the concrete in the uniformly mixed state is normal, the discharge port is opened by two-thirds; when the prediction result is that the fluidity of the concrete in the uniformly mixed state is good, the discharge port is opened by one-half.

[0019] The advantages or beneficial effects of the above technical solution at least include: by obtaining the current signal of the concrete mixing process, establishing a neural network model, monitoring the concrete mixing state and intelligently unloading the concrete, the mixing state at each moment can be continuously judged, so as to timely determine the time point when the concrete is mixed in a uniform state, so that the mixing and unloading can be stopped in time, ensuring that the concrete discharge is in a uniform state while avoiding unnecessary waste of mixing time, thereby improving the quality and efficiency of production; at the same time, by predicting the fluidity of the concrete in the uniform mixing state and controlling the opening of the discharge port according to the predicted result of the fluidity, it is possible to avoid the situation where the amount of temporary storage material is too much due to unloading too quickly when the fluidity is good, or the situation where the fluidity is poor and the unloading time is too long due to blockage can be avoided, making the mixing production of concrete more stable and orderly.

[0020] In a second aspect, the present invention provides a device for intelligent concrete unloading based on real-time monitoring of current, comprising a mixer motor, a control cabinet, a current clamp, a data acquisition card, a computer and a discharge port opening controller, wherein the mixer motor is electrically connected to the control cabinet, the current clamp is connected between the mixer motor and the control cabinet, the current clamp is connected to the computer through the data acquisition card, the discharge port opening controller is electrically connected to the computer, the data acquisition card collects the current signal of the mixer motor through the current clamp and transmits it to the computer for storage, the computer is used to execute the above-mentioned intelligent concrete unloading method based on real-time monitoring of current, and controls the start and stop of the mixer motor and the size and closing of the discharge port opening by the discharge port opening controller according to the decision result of the above-mentioned intelligent concrete unloading method based on real-time monitoring of current.

[0021] The advantages or beneficial effects of the above technical solution include at least: through the cooperation of the mixer motor, control cabinet, current clamp, data acquisition card, computer and discharge port opening controller, the above-mentioned intelligent concrete unloading method based on real-time monitoring of current can be executed, so that the start and stop of the mixer motor and the discharge port opening controller can be controlled according to the decision result to control the size and closing of the discharge port opening, ensuring that the concrete discharge is in a uniform state while avoiding unnecessary waste of mixing time, improving the quality and efficiency of production, and being able to control the opening of the discharge port, so as to avoid excessive storage bin material due to too fast unloading when the fluidity is good, or blockage and too long unloading time when the fluidity is poor, making the concrete mixing production more stable and orderly. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The accompanying drawings illustrate exemplary embodiments of the present invention and together with the description serve to explain the principles of the present invention. These drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification.

[0023] Figure 1 A schematic diagram of a device for intelligent concrete unloading according to an exemplary embodiment of the present invention is shown;

[0024] Figure 2 A schematic diagram of a concrete mixing state prediction model according to an exemplary embodiment of the present invention is shown;

[0025] Figure 3 A schematic diagram of a concrete fluidity prediction model according to an exemplary embodiment of the present invention is shown;

[0026] Figure 4 FIG. 4 is a graph schematically showing a current signal according to an exemplary embodiment of the present invention.

[0027] Description of reference numerals:

[0028] 1. Mixer motor; 2. Control cabinet; 3. Current clamp; 4. Data acquisition card; 5. Computer; 6. Discharge port opening controller. DETAILED DESCRIPTION

[0029] Embodiments of the present invention will be described in more detail below with reference to the accompanying drawings. Although certain embodiments of the present invention are shown in the accompanying drawings, it should be understood that the present invention can be implemented in various forms and should not be construed as being limited to the embodiments described herein, which are instead provided for a more thorough and complete understanding of the present invention. It should be understood that the drawings and embodiments of the present invention are only for exemplary purposes and are not intended to limit the scope of protection of the present invention.

[0030] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0031] It should be understood that the various steps described in the method embodiments of the present invention may be performed in different orders and / or in parallel. In addition, the method embodiments may include additional steps and / or omit the steps shown. The scope of the present invention is not limited in this respect.

[0032] The term "including" and its variations used in this document are open inclusions, that is, "including but not limited to". The term "based on" means "based at least in part on". The term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one other embodiment"; the term "some embodiments" means "at least some embodiments". Relevant definitions of other terms will be given in the following description. It should be noted that the concepts of "first", "second", etc. mentioned in the present invention are only used to distinguish different devices, modules or units, and are not used to limit the order or interdependence of the functions performed by these devices, modules or units.

[0033] It should be noted that the modifications of "one" and "plurality" mentioned in the present invention are illustrative rather than restrictive, and those skilled in the art should understand that, unless otherwise clearly indicated in the context, it should be understood as "one or more".

[0034] The names of the messages or information exchanged between multiple devices in the embodiments of the present invention are only used for illustrative purposes, and are not used to limit the scope of these messages or information.

[0035] See also Figures 2 to 4 , an embodiment of the present invention provides a method for intelligent concrete unloading based on real-time monitoring of current, comprising the following steps:

[0036] S1. Obtaining the current signal of the concrete mixing process: real-time acquisition of the mixer main shaft current signal during the concrete mixing process;

[0037] The acquisition time period of the mixer main shaft current signal starts when the mixer starts to feed and ends when the mixer starts to discharge, that is, the mixer stops stirring.

[0038] S2. Establish a neural network model: obtain the production volume, production intensity, and environmental variables of concrete, take the production volume, production intensity, environmental variables and current signal of concrete as input, take the mixing state and fluidity of concrete as output, establish and train a concrete mixing state prediction model that associates the current signal with the concrete mixing state and a concrete fluidity prediction model that associates the current signal with the concrete fluidity. The concrete fluidity prediction model determines whether to execute the prediction based on the output result of the concrete mixing state prediction model. Since in the concrete mixing process, the production volume, production intensity and environmental factors are fixed variables before each batch of concrete is mixed, and the input current signal is a variable that changes with time, therefore, the established concrete mixing state prediction model and concrete fluidity prediction model are both associated with the current signal.

[0039] The stirring state includes uniform and non-uniform. Figure 4 In the concrete mixing state prediction model, the mixer main shaft current signal outputs a current value per second, so the model input will be updated every second. After each second of input, the model will judge the concrete uniformity state of the mixing model at that moment, while other model neuron inputs remain unchanged; the way to judge the uniform mixing state in the concrete mixing state prediction model is to change continuously with the current input. When the mixing state output by the model for three consecutive moments is that the concrete is mixed uniformly, it is considered that the pot of concrete has entered the uniform concrete state at this moment.

[0040] In step S2, when the output result of the concrete mixing state prediction model is uniform, the concrete fluidity prediction model performs the prediction of concrete fluidity; when the output result of the concrete mixing state prediction model is uneven, the concrete fluidity prediction model does not perform the prediction of concrete fluidity.

[0041] Concrete fluidity includes poor fluidity, normal fluidity and good fluidity.

[0042] Reference Figure 2 and Figure 3 The concrete mixing state prediction model and the concrete fluidity prediction model are composed of an input layer, a first hidden layer, a second hidden layer and an output layer connected in sequence. The input layer is used to receive production volume, production intensity, environmental variables and current signals. The first hidden layer includes 16 neurons and the second hidden layer includes 32 neurons. The first hidden layer and the second hidden layer are used to extract features and perform nonlinear mapping on the input of the input layer.

[0043] S3. Concrete mixing state monitoring: obtain the production volume, production intensity, environmental variables and current signals of concrete in the actual production process, and input them into the concrete mixing state prediction model and concrete fluidity prediction model to obtain the prediction results;

[0044] In step S3, the prediction result obtained is one of uneven mixing, poor fluidity of concrete in a uniform mixing state, normal fluidity, or good fluidity.

[0045] S4. Intelligent concrete unloading: Make intelligent concrete unloading decisions based on the prediction results of S3, and obtain the decision results of whether to continue mixing concrete or stop mixing and open the size of the unloading port at the same time.

[0046] Among them, the intelligent unloading decision-making method is that when the prediction result is uneven mixing, the mixer continues to stir; when the prediction result is that the fluidity of the concrete in the uniform mixing state is poor, normal or good, the mixer stops stirring and controls the size of the discharge port to unload.

[0047] When the prediction result shows that the fluidity of the concrete in the evenly mixed state is poor, the discharge port is fully opened; when the prediction result shows that the fluidity of the concrete in the evenly mixed state is normal, the discharge port is opened by two-thirds; when the prediction result shows that the fluidity of the concrete in the evenly mixed state is good, the discharge port is opened by one-half.

[0048] By adopting the above method, through the steps of obtaining the current signal of the concrete mixing process, establishing a neural network model, monitoring the concrete mixing state and intelligently unloading the concrete, the mixing state at each moment can be continuously judged, so as to timely determine the time point when the concrete is mixed in a uniform state, so that the mixing and unloading can be stopped in time, ensuring that the concrete discharge is in a uniform state while avoiding the waste of unnecessary mixing time, thereby improving the quality and efficiency of production; at the same time, by predicting the fluidity of the concrete in the uniform mixing state and controlling the opening of the discharge port according to the predicted result of the fluidity, it is possible to avoid the situation where the amount of temporary storage material is too much due to unloading too quickly when the fluidity is good, or the situation where the fluidity is poor and the unloading time is too long due to blockage, so that the mixing production of concrete is more stable and orderly.

[0049] See also Figures 1 to 4 The embodiment of the present invention provides a device for intelligent concrete unloading based on real-time monitoring of current, comprising a mixer motor 1, a control cabinet 2, a current clamp 3, a data acquisition card 4, a computer 5 and a discharge port opening controller 6, referring to Figure 1The mixer motor 1 is electrically connected to the control cabinet 2, the current clamp 3 is connected between the mixer motor 1 and the control cabinet 2, the current clamp 3 is connected to the computer 5 through the data acquisition card 4, the discharge port opening controller 6 is electrically connected to the computer 5, the data acquisition card 4 collects the current signal of the mixer motor 1 through the current clamp 3 and transmits it to the computer 5 for storage, the computer 5 is used to execute the above-mentioned intelligent concrete unloading method based on real-time monitoring of current, and control the start and stop of the mixer motor 1 and the discharge port opening controller 6 to control the size and closing of the discharge port opening according to the decision result of the above-mentioned intelligent concrete unloading method based on real-time monitoring of current.

[0050] By adopting the above structure, through the cooperation of the mixer motor 1, the control cabinet 2, the current clamp 3, the data acquisition card 4, the computer 5 and the discharge port opening controller 6, the above-mentioned intelligent concrete unloading method based on real-time monitoring of current can be executed, so that the start and stop of the mixer motor 1 and the discharge port opening controller 6 can be controlled according to the decision result to control the size and closing of the discharge port opening, thereby ensuring that the concrete discharge is in a uniform state while avoiding the waste of unnecessary mixing time, improving the quality and efficiency of production, and being able to control the opening of the discharge port, thereby avoiding the situation where the amount of temporary storage material is too much due to unloading too quickly when the fluidity is good, or the situation where the fluidity is poor and the discharge time is too long, making the mixing production of concrete more stable and orderly.

[0051] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limitations on the present invention.

[0052] It should be understood by those skilled in the art that the above embodiments are only for the purpose of clearly illustrating the present invention, and are not intended to limit the scope of the present invention. For those skilled in the art, other changes or modifications may be made based on the above invention, and these changes or modifications are still within the scope of the present invention.

Claims

1. A method for intelligent concrete unloading based on real-time monitoring of current, characterized in that: The following steps are included: S1. Obtaining the current signal of the concrete mixing process: real-time acquisition of the mixer main shaft current signal during the concrete mixing process; S2. Establish a neural network model: obtain the production volume, production intensity, and environmental variables of concrete, take the production volume, production intensity, environmental variables, and current signal of concrete as input, take the mixing state and fluidity of concrete as output, establish and train a concrete mixing state prediction model that associates the current signal with the concrete mixing state and a concrete fluidity prediction model that associates the current signal with the concrete fluidity, and the concrete fluidity prediction model determines whether to perform the prediction based on the output result of the concrete mixing state prediction model; S3. Concrete mixing state monitoring: obtain the production volume, production intensity, environmental variables and current signals of concrete in the actual production process, and input them into the concrete mixing state prediction model and concrete fluidity prediction model to obtain the prediction results; S4. Intelligent concrete unloading: Make intelligent concrete unloading decisions based on the prediction results of S3, and obtain the decision results of whether to continue mixing concrete or stop mixing and open the size of the unloading port at the same time.

2. The intelligent concrete unloading method based on real-time monitoring of current according to claim 1 is characterized in that: The acquisition time period of the mixer main shaft current signal starts when the mixer starts to feed and ends when the mixer starts to discharge.

3. The intelligent concrete unloading method based on real-time monitoring of current according to claim 1, characterized in that: The stirring state includes uniform and non-uniform.

4. The intelligent concrete unloading method based on real-time monitoring of current according to claim 3 is characterized in that: In the step S2, when the output result of the concrete mixing state prediction model is uniform, the concrete fluidity prediction model performs the prediction of concrete fluidity; when the output result of the concrete mixing state prediction model is non-uniform, the concrete fluidity prediction model does not perform the prediction of concrete fluidity.

5. The intelligent concrete unloading method based on real-time monitoring of current according to claim 4 is characterized in that: The concrete fluidity includes poor fluidity, normal fluidity and good fluidity.

6. The intelligent concrete unloading method based on real-time monitoring of current according to claim 5, characterized in that: In the step S3, the prediction result obtained is one of uneven mixing, poor fluidity of concrete in a uniform mixing state, normal fluidity or good fluidity.

7. The intelligent concrete unloading method based on real-time monitoring of current according to claim 1, characterized in that: The concrete mixing state prediction model and the concrete fluidity prediction model are both composed of an input layer, a first hidden layer, a second hidden layer and an output layer connected in sequence. The input layer is used to receive production volume, production intensity, environmental variables and current signals. The first hidden layer includes 16 neurons and the second hidden layer includes 32 neurons.

8. The intelligent concrete unloading method based on real-time monitoring of current according to claim 6, characterized in that: The intelligent unloading decision method is that when the prediction result is uneven mixing, the mixer continues to stir; when the prediction result is that the concrete has poor fluidity, normal fluidity or good fluidity in the uniform mixing state, the mixer stops stirring and controls the size of the unloading port to unload.

9. The intelligent concrete unloading method based on real-time monitoring of current according to claim 8, characterized in that: When the prediction result shows that the fluidity of the concrete in the uniformly mixed state is poor, the discharge port is fully opened; when the prediction result shows that the fluidity of the concrete in the uniformly mixed state is normal, the discharge port is opened by two-thirds; when the prediction result shows that the fluidity of the concrete in the uniformly mixed state is good, the discharge port is opened by one-half.

10. An intelligent concrete unloading device based on real-time monitoring of current, characterized in that: The invention comprises a mixer motor, a control cabinet, a current clamp, a data acquisition card, a computer and a discharge port opening controller, wherein the mixer motor is electrically connected to the control cabinet, the current clamp is connected between the mixer motor and the control cabinet, the current clamp is connected to the computer through the data acquisition card, the discharge port opening controller is electrically connected to the computer, the data acquisition card collects the current signal of the mixer motor through the current clamp and transmits it to the computer for storage, the computer is used to execute the intelligent concrete unloading method based on real-time monitoring of current as described in any one of claims 1-9, and controls the start and stop of the mixer motor and the size and closing of the discharge port opening by the discharge port opening controller according to the decision result of the intelligent concrete unloading method based on real-time monitoring of current as described in any one of claims 1-9.

Images