High-viscosity concrete surface finishing system with steel fibers

Abstract

The invention provides a high-viscosity concrete surface finishing system with steel fibers, and belongs to the technical field of concrete surface finishing, the high-viscosity concrete surface finishing system with steel fibers comprises a base, a support frame, a mixing drum, a driving device, a steel fiber dispersing device, a concrete conveying device, a surface finishing roller and a surface finishing pressing plate; the base is in a rectangular flat plate shape, and the supporting frame is fixedly installed on the base. The supporting frame comprises a left stand column, a right stand column and a top beam, the left stand column and the right stand column are vertically arranged on the base, and the top beam is horizontally connected with the top ends of the left stand column and the right stand column; the mixing drum is cylindrical, and the two ends of the mixing drum are rotationally mounted on the left stand column and the right stand column through bearing seats respectively; the driving device is installed on the right stand column, and an output shaft of the driving device is in transmission connection with the right end of the stirring barrel; the problem that steel fibers are difficult to thoroughly disperse in existing stirring equipment can be solved.

Description

Technical Field

[0001] The invention belongs to the technical field of concrete finishing, and in particular relates to a high-viscosity concrete finishing system with steel fibers. Background Art

[0002] In recent years, due to the accelerated urbanization process and the pace of infrastructure construction, the demand for high-performance concrete products in the construction and infrastructure fields has been increasing. Generally, a large amount of fly ash, mineral admixtures or chemical admixtures need to be added during the preparation of high-viscosity concrete to enhance its cohesion and fluidity. However, the greater the amount of these additives added, the more complex the internal pore structure of the concrete, and problems such as segregation are prone to occur, which seriously affects the construction performance and final mechanical properties of the concrete. To solve this problem, new concrete mix design and construction technology have gradually attracted the attention of the industry.

[0003] In this context, adding steel fiber to high viscosity concrete can not only improve the tensile strength and toughness of concrete, but also significantly improve its anti-cracking performance. How to achieve uniform dispersion of steel fiber in high viscosity concrete has become one of the key factors affecting the quality of this concrete product.

[0004] At present, in the preparation process of steel fiber reinforced high viscosity concrete, the common practice is to mix steel fiber with concrete raw materials in a mixing station or a mixer truck. However, due to the poor fluidity of high viscosity concrete itself and the large fiber length, it is difficult to achieve thorough dispersion of steel fiber in traditional mixing equipment, which is prone to agglomeration or uneven distribution, thereby reducing the overall performance of concrete. Therefore, it is urgent to develop a special steel fiber dispersion device that can efficiently and evenly disperse steel fiber during concrete mixing, laying the foundation for subsequent molding and finishing processes.

[0005] On the other hand, there are still some technical difficulties that need to be solved in the molding process of high-viscosity concrete products. First, due to the poor fluidity of high-viscosity concrete, it is difficult to form naturally without any external force, and special finishing equipment is required for roller forming. However, most of the existing concrete finishing equipment is for concrete of conventional strength and viscosity, which is difficult to meet the molding requirements of high-viscosity concrete. Secondly, due to the complex internal structure of high-viscosity concrete, surface quality problems such as corrugations and rough surfaces are prone to occur during the finishing process, which affects the performance of the product. Therefore, the development of a reliable high-viscosity concrete finishing system has become a technical problem that the industry urgently needs to solve. Summary of the invention

[0006] In view of this, the present invention provides a high-viscosity concrete finishing system with steel fibers, which can solve the problem that it is difficult to thoroughly disperse the steel fibers in existing mixing equipment.

[0007] The present invention is achieved in that:

[0008] The present invention provides a high-viscosity concrete finishing system with steel fibers, which includes: a base, a support frame, a mixing drum, a driving device, a steel fiber dispersing device, a concrete conveying device, a finishing roller and a finishing pressing plate; the base is in the shape of a rectangular flat plate, and the support frame is fixedly installed on the base; the support frame includes a left column, a right column and a top beam, the left column and the right column are vertically arranged on the base, and the top beam horizontally connects the top ends of the left column and the right column; the mixing drum is in the shape of a cylinder, and the two ends of the mixing drum are rotatably installed on the left column and the right column respectively through a bearing seat; the driving device is installed on On the right column, the output shaft of the driving device is transmission-connected with the right end of the mixing drum; the steel fiber dispersing device is installed on the top beam, and the discharge port of the steel fiber dispersing device is aligned with the upper opening of the mixing drum; the concrete conveying device is installed on the left column, and the discharge pipe of the concrete conveying device extends into the mixing drum; the dough collecting roller is a hollow cylindrical shape, and the two ends of the dough collecting roller are rotatably mounted on the left column and the right column respectively through bearings, and the dough collecting roller is located directly below the mixing drum; the dough collecting pressure plate is a long strip, and the dough collecting pressure plate is mounted on the top beam through multiple hydraulic cylinders, and the dough collecting pressure plate is located directly above the dough collecting roller.

[0009] The technical effects of a high-viscosity concrete finishing system with steel fibers provided by the present invention are as follows: 1. In view of the problem of difficulty in dispersing steel fibers inside high-viscosity concrete, the system adopts a special steel fiber dispersing device, including a storage hopper, a spiral conveying pipe, a vibrating screen and a dispersing disk, etc., which can effectively disperse the pre-added steel fibers into the concrete in the mixing drum, ensure the uniform distribution of the steel fibers in the concrete matrix, and create good prerequisites for subsequent forming and finishing.

[0010] 2. In view of the problem that existing concrete finishing equipment is difficult to meet the requirements of high-viscosity concrete molding, this system has designed a finishing mechanism with heating and compacting functions, including a hollow cylindrical finishing roller and a long strip finishing plate. The finishing roller is equipped with a heating device inside, which can preheat the roller body to a certain temperature, produce good rheological interaction when in contact with the high-temperature concrete surface, and effectively improve the molding performance of the concrete. At the same time, the finishing plate precisely controls the pressure through the hydraulic cylinder to evenly compact the concrete surface, ensuring that the product finally reaches the ideal flat and smooth state.

[0011] 3. The system is also equipped with an automated cleaning device, including a water tank, a high-pressure water pump and a water spray pipe, which can regularly perform high-pressure water washing on key components such as the inner wall of the mixing drum, the mixing shaft and the dough collecting roller to keep the equipment clean and sanitary, extend its service life and improve production efficiency.

[0012] 4. The operating parameters of each component in the system, such as stirring speed, heating temperature, compaction pressure, etc., are all monitored and precisely controlled in real time through the controller. At the same time, multiple sensors such as temperature, pressure and position are integrated to form a closed-loop control, ensuring that the entire production process is highly automated and intelligent, greatly improving the stability and reliability of the process.

[0013] In summary, the high-viscosity concrete finishing system with steel fibers designed in the present invention effectively solves the key problems existing in the prior art. It can not only ensure the uniform dispersion of steel fibers in concrete, but also realize the precise molding of high-viscosity concrete and automatic cleaning of equipment, which greatly improves the production quality and efficiency of such high-performance concrete products and provides advanced process technology support for future infrastructure construction.

[0014] On the basis of the above technical solution, the high viscosity concrete finishing system with steel fiber of the present invention can also be improved as follows:

[0015] Among them, a plurality of stirring blades are fixedly installed axially on the inner wall of the mixing drum, and the stirring blades are distributed in a spiral shape; a stirring shaft is also coaxially arranged inside the mixing drum, and the two ends of the stirring shaft are rotatably installed on the left end cover and the right end cover of the mixing drum through bearing seats respectively; a plurality of stirring arms are fixedly installed axially on the mixing shaft, and the stirring arms are distributed radially; the right end of the stirring shaft is connected to the output shaft of the driving device through a coupling.

[0016] Furthermore, the steel fiber dispersion device includes a storage hopper, a spiral conveying pipe, a vibrating screen and a dispersion disk; the storage hopper is funnel-shaped and fixedly mounted on the top beam; the feed end of the spiral conveying pipe is connected to the discharge port of the storage hopper, and a spiral conveying blade is provided in the spiral conveying pipe; the vibrating screen is installed below the discharge end of the spiral conveying pipe, and a plurality of sieve holes are provided on the vibrating screen; the dispersion disk is installed below the vibrating screen, and the dispersion disk is disc-shaped, the upper surface of the dispersion disk is conical, and a plurality of evenly distributed discharge ports are provided on the edge of the dispersion disk.

[0017] Furthermore, the concrete conveying device includes a hopper, a spiral pump and a conveying pipe; the hopper is funnel-shaped and fixedly mounted on a left column; the spiral pump is mounted below the hopper, and the feed port of the spiral pump is connected to the discharge port of the hopper; one end of the conveying pipe is connected to the discharge port of the spiral pump, and the other end of the conveying pipe extends into the mixing drum, and a nozzle is provided at the end of the conveying pipe.

[0018] Furthermore, the surface of the dough collecting roller is provided with a plurality of evenly distributed grooves, which are arranged in a spiral shape; a heating device is provided inside the dough collecting roller, and the heating device includes an electric heating wire and a temperature sensor; a water inlet and a water outlet are provided at one end of the dough collecting roller, and the water inlet and the water outlet are respectively connected to an external water source and a drain pipe through a rotating joint.

[0019] Furthermore, the bottom surface of the dough collecting pressure plate is provided with a plurality of evenly distributed embossings, which cooperate with the grooves on the surface of the dough collecting roller; the dough collecting pressure plate is connected to the top beam through at least three hydraulic cylinders, the piston rod ends of the hydraulic cylinders are hinged to the dough collecting pressure plate, and the cylinder bodies of the hydraulic cylinders are fixedly connected to the top beam; the hydraulic cylinders are connected to the hydraulic pump station through hydraulic pipelines, and the hydraulic pump station is installed on a base.

[0020] Furthermore, it also includes a cleaning device, which includes a water tank, a high-pressure water pump and a water spray pipe; the water tank is fixedly installed on the base, and the water tank is connected to the water inlet of the high-pressure water pump through a pipeline; the high-pressure water pump is installed on the base, and the water outlet of the high-pressure water pump is connected to the water spray pipe through a pipeline; the water spray pipe is arranged along the length direction of the mixing drum, and a plurality of nozzles are evenly distributed on the water spray pipe, and the nozzles face the inner wall of the mixing drum.

[0021] It also includes a control box, which is installed on the base; a controller is arranged in the control box, and the controller is electrically connected to the driving device, the steel fiber dispersing device, the concrete conveying device, the heating device of the dough roller, the hydraulic pump station and the high-pressure water pump.

[0022] Furthermore, it also includes multiple sensors, including a temperature sensor, a pressure sensor and a position sensor; the temperature sensor is installed on the mixing drum and the dough roller, and is used to detect the temperature of the concrete in the mixing drum and the surface temperature of the dough roller; the pressure sensor is installed on the hydraulic cylinder, and is used to detect the working pressure of the hydraulic cylinder; the position sensor is installed on the dough pressing plate, and is used to detect the position of the dough pressing plate; the sensors are all electrically connected to the controller.

[0023] Furthermore, a concrete finishing control module is provided in the controller, and the concrete finishing control module is used to control the steel fiber dispersion, concrete mixing and finishing process; the concrete finishing control module performs the following steps:

[0024] S10, receiving data from the temperature sensor, the pressure sensor and the position sensor, and initializing the system according to preset parameters;

[0025] S20, controlling the steel fiber dispersing device to start, and evenly dispersing the steel fibers into the mixing drum;

[0026] S30, controlling the concrete conveying device to start and convey a predetermined amount of concrete raw materials into the mixing drum;

[0027] S40, controlling the driving device to start, driving the mixing drum and the mixing shaft to rotate, and fully mixing the concrete and the steel fibers;

[0028] S50, monitoring the temperature of concrete in the mixing drum, and when the temperature reaches a preset value, controlling the heating device of the dough collecting roller to start, heating the dough collecting roller to a predetermined temperature;

[0029] S60, controlling the inclination of the mixing drum to slowly pour the evenly mixed high-viscosity concrete onto the finishing roller;

[0030] S70, control the hydraulic pump station to start, drive the hydraulic cylinder to drive the finishing plate to descend, and compact the concrete on the finishing roller;

[0031] S80, according to the data fed back by the position sensor, adjust the pressure and position of the finishing plate to ensure that the concrete surface is flat;

[0032] S90, when the dough collecting process is completed, the cleaning device is controlled to start, and the mixing drum, the mixing shaft and the dough collecting roller are cleaned to complete a working cycle.

[0033] In step S40, the calculation of the stirring efficiency is specifically expressed as follows:

[0034]

[0035] In the formula, E m is the mixing efficiency; ω is the angular velocity of the mixing shaft (rad / s); R is the radius of the mixing drum (m); ρ is the density of concrete (kg / m 3 ), μ is the dynamic viscosity of concrete (Pa·s), k1, k2, k3 are unknown coefficients, and ε is the error term.

[0036] The parameter acquisition method is as follows: ω is directly measured by the speed sensor of the driving device; R is the design parameter of the mixing drum, which can be directly measured; ρ is determined by the following steps: 1. Take a certain volume of concrete sample; 2. Use a precision balance to weigh the sample mass; 3. Calculate the density Where m is the sample mass (kg), V is the sample volume (m 3 ).

[0037] μ is determined by the following steps: 1. Use a rotational viscometer to measure the shear stress τ (Pa) and shear rate of concrete 2. According to the formula Calculate the dynamic viscosity.

[0038] In step S50, the concrete temperature prediction model is specifically expressed as follows:

[0039]

[0040] Where, T(t) is the concrete temperature at time t (℃); T0 is the initial temperature (℃); Q h is the hydration heat release rate (J / s); m c is the mass of concrete (kg); c p is the specific heat capacity of concrete (J / (kg·℃)); τ is the thermal time constant (s); A is the ambient temperature fluctuation amplitude (℃); φ is the phase angle (rad); t is the time (s); and ε is the error term.

[0041] The parameter acquisition method is as follows: T0 is directly measured by the temperature sensor; Q h Calculated by the following formula: where q c is the potential hydration heat of cement (J / kg), m cem is the mass of cement (kg), is the rate of change of hydration degree, which can be obtained through experiments; m c Obtained by weighing; c p Determine by experiment: 1. Heat a concrete sample of known mass to a certain temperature; 2. Measure the amount of heat required for heating; 3. According to the formula Calculate the specific heat capacity, where Q is the amount of heating (J) and ΔT is the temperature change (°C).

[0042] In step S70, the hydraulic cylinder pressure control model is specifically expressed as follows:

[0043]

[0044] Where, P(t) is the hydraulic cylinder pressure at time t (Pa); P0 is the initial pressure (Pa); K p ,K i ,K d are proportional, integral, and differential control parameters respectively; e(t) is the pressure error (Pa), e(t) = P set -P(t),P set is the set pressure (Pa); ε is the error term.

[0045] The parameter acquisition method is: P0 is directly measured by the pressure sensor to obtain K p ,K i ,K d Determine by Ziegler-Nichols tuning method: 1. Set K i and K d Set to 0 and gradually increase K p Until the system continues to oscillate, record the K at this time p K u, the oscillation period is T u ; 2. Calculate according to the formula: 0.6K u ,

[0046] In step S80, the concrete surface flatness evaluation model is specifically expressed as follows:

[0047]

[0048] Where, F is the surface flatness index; N is the number of measurement points; h i is the height of the ith measurement point (mm); is the average height (mm); β, γ are weight coefficients; ε is the error term.

[0049] The parameter acquisition method is: i Obtained through measurement with a laser scanner or 3D scanner; By formula Calculation; β, γ are obtained by fitting multiple sets of experimental data and usually range from 0 to 1.

[0050] Compared with the prior art, the high viscosity concrete finishing system with steel fibers provided by the present invention has the following beneficial effects:

[0051] 1. Aiming at the problem of difficult dispersion of steel fibers in high-viscosity concrete, this system adopts a special steel fiber dispersion device, including a storage hopper, a spiral conveying pipe, a vibrating screen and a dispersion plate, which can effectively disperse the pre-added steel fibers into the concrete in the mixing drum, ensuring the uniform distribution of the steel fibers in the concrete matrix, creating good prerequisites for subsequent forming and finishing.

[0052] 2. In view of the problem that existing concrete finishing equipment is difficult to meet the requirements of high-viscosity concrete molding, this system has designed a finishing mechanism with heating and compacting functions, including a hollow cylindrical finishing roller and a long strip finishing plate. The finishing roller is equipped with a heating device inside, which can preheat the roller body to a certain temperature, produce good rheological interaction when in contact with the high-temperature concrete surface, and effectively improve the molding performance of the concrete. At the same time, the finishing plate precisely controls the pressure through the hydraulic cylinder to evenly compact the concrete surface, ensuring that the product finally reaches the ideal flat and smooth state.

[0053] 3. The system is also equipped with an automated cleaning device, including a water tank, a high-pressure water pump and a water spray pipe, which can regularly perform high-pressure water washing on key components such as the inner wall of the mixing drum, the mixing shaft and the dough collecting roller to keep the equipment clean and sanitary, extend its service life and improve production efficiency.

[0054] 4. The operating parameters of each component in the system, such as stirring speed, heating temperature, compaction pressure, etc., are all monitored and precisely controlled in real time through the controller. At the same time, multiple sensors such as temperature, pressure and position are integrated to form a closed-loop control, ensuring that the entire production process is highly automated and intelligent, greatly improving the stability and reliability of the process.

[0055] In summary, the high-viscosity concrete finishing system with steel fibers designed in the present invention effectively solves the key problems existing in the prior art. It can not only ensure the uniform dispersion of steel fibers in concrete, but also realize the precise molding of high-viscosity concrete and automatic cleaning of equipment, which greatly improves the production quality and efficiency of such high-performance concrete products and provides advanced process technology support for future infrastructure construction. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings in the following description 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 labor.

[0057] Figure 1 It is a structural schematic diagram of a high viscosity concrete finishing system with steel fibers;

[0058] In the accompanying drawings, the components represented by the reference numerals are listed as follows:

[0059] 10. Base; 100. Control box; 20. Support frame; 21. Left column; 22. Right column; 23. Top beam; 30. Mixing barrel; 31. Mixing blade; 32. Mixing shaft; 33. Mixing arm; 40. Driving device; 50. Steel fiber dispersing device; 51. Storage hopper; 52. Screw conveying pipe; 53. Vibrating screen; 54. Dispersing disc; 60. Concrete conveying device; 61. Hopper; 62. Screw pump; 63. Conveying pipe; 70. Dough collecting roller; 71. Groove; 80. Dough collecting plate; 90. Cleaning device; 91. Water tank; 92. High-pressure water pump; 93. Water spraying pipe. DETAILED DESCRIPTION

[0060] In order to make the purpose, technical solution and advantages of the embodiments of the present invention more clear, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0061] like Figure 1As shown in the figure, it is an embodiment of a high-viscosity concrete finishing system with steel fibers provided by the present invention. In this embodiment, it includes: a base 10, a support frame 20, a mixing drum 30, a driving device 40, a steel fiber dispersing device 50, a concrete conveying device 60, a finishing roller 70 and a finishing pressing plate 80; the base is in the shape of a rectangular flat plate, and the support frame is fixedly installed on the base; the support frame includes a left column 21, a right column 22 and a top beam 23, the left column and the right column are vertically arranged on the base, and the top beam horizontally connects the top ends of the left column and the right column; the mixing drum is cylindrical, and the two ends of the mixing drum are rotatably mounted through bearing seats Installed on the left column and the right column; the driving device is installed on the right column, and the output shaft of the driving device is connected to the right end of the mixing drum; the steel fiber dispersing device is installed on the top beam, and the discharge port of the steel fiber dispersing device is aligned with the upper opening of the mixing drum; the concrete conveying device is installed on the left column, and the discharge pipe of the concrete conveying device extends into the mixing drum; the dough collecting roller is a hollow cylindrical shape, and the two ends of the dough collecting roller are rotatably installed on the left column and the right column through bearings respectively, and the dough collecting roller is located directly below the mixing drum; the dough collecting pressure plate is a long strip, and the dough collecting pressure plate is installed on the top beam through multiple hydraulic cylinders, and the dough collecting pressure plate is located directly above the dough collecting roller.

[0062] Among them, in the above technical scheme, a plurality of stirring blades 31 are fixedly installed axially on the inner wall of the mixing drum, and the stirring blades are distributed in a spiral shape; a stirring shaft 32 is also coaxially provided inside the mixing drum, and both ends of the stirring shaft are rotatably installed on the left end cover and the right end cover of the mixing drum through bearing seats respectively; a plurality of stirring arms 33 are fixedly installed axially on the mixing shaft, and the stirring arms are distributed radially; the right end of the stirring shaft is connected to the output shaft of the driving device through a coupling.

[0063] Furthermore, in the above technical solution, the steel fiber dispersion device includes a storage hopper 51, a spiral conveying pipe 52, a vibrating screen 53 and a dispersion disk 54; the storage hopper is funnel-shaped and fixedly mounted on the top beam; the feed end of the spiral conveying pipe is connected to the discharge port of the storage hopper, and a spiral conveying blade is arranged in the spiral conveying pipe; the vibrating screen is installed below the discharge end of the spiral conveying pipe, and a plurality of sieve holes are arranged on the vibrating screen; the dispersion disk is installed below the vibrating screen, and the dispersion disk is disc-shaped, the upper surface of the dispersion disk is conical, and a plurality of evenly distributed discharge ports are arranged on the edge of the dispersion disk.

[0064] Furthermore, in the above technical solution, the concrete conveying device includes a hopper 61, a screw pump 62 and a conveying pipe 63; the hopper is funnel-shaped and fixedly mounted on the left column; the screw pump is mounted below the hopper, and the feed port of the screw pump is connected to the discharge port of the hopper; one end of the conveying pipe is connected to the discharge port of the screw pump, and the other end of the conveying pipe extends into the mixing drum, and a nozzle is provided at the end of the conveying pipe.

[0065] Furthermore, in the above technical solution, the surface of the dough collecting roller is provided with a plurality of evenly distributed grooves 71, which are arranged in a spiral shape; a heating device is provided inside the dough collecting roller, and the heating device includes an electric heating wire and a temperature sensor; a water inlet and a water outlet are provided at one end of the dough collecting roller, and the water inlet and the water outlet are respectively connected to an external water source and a drain pipe through a rotating joint.

[0066] Furthermore, in the above technical solution, the bottom surface of the dough collecting plate is provided with a plurality of evenly distributed embossings, which cooperate with the grooves on the surface of the dough collecting roller; the dough collecting plate is connected to the top beam through at least three hydraulic cylinders, the piston rod ends of the hydraulic cylinders are hinged to the dough collecting plate, and the cylinder bodies of the hydraulic cylinders are fixedly connected to the top beam; the hydraulic cylinders are connected to the hydraulic pump station through hydraulic pipelines, and the hydraulic pump station is installed on a base.

[0067] Furthermore, in the above technical scheme, a cleaning device 90 is also included, which includes a water tank 91, a high-pressure water pump 92 and a water spray pipe 93; the water tank is fixedly installed on the base, and the water tank is connected to the water inlet of the high-pressure water pump through a pipe; the high-pressure water pump is installed on the base, and the water outlet of the high-pressure water pump is connected to the water spray pipe through a pipe; the water spray pipe is arranged along the length direction of the mixing drum, and a plurality of nozzles are evenly distributed on the water spray pipe, and the nozzles are facing the inner wall of the mixing drum.

[0068] Among them, in the above technical scheme, it also includes a control box, which is installed on the base; a controller is provided in the control box, and the controller is electrically connected to the driving device, steel fiber dispersion device, concrete conveying device, heating device of the dough roller, hydraulic pump station and high-pressure water pump respectively.

[0069] Furthermore, in the above technical scheme, it also includes multiple sensors, including temperature sensors, pressure sensors and position sensors; the temperature sensor is installed on the mixing drum and the dough roller, and is used to detect the temperature of the concrete in the mixing drum and the surface temperature of the dough roller; the pressure sensor is installed on the hydraulic cylinder, and is used to detect the working pressure of the hydraulic cylinder; the position sensor is installed on the dough pressing plate, and is used to detect the position of the dough pressing plate; the sensors are all electrically connected to the controller.

[0070] Furthermore, in the above technical solution, a concrete finishing control module is provided in the controller, and the concrete finishing control module is used to control the steel fiber dispersion, concrete mixing and finishing process; the concrete finishing control module performs the following steps:

[0071] S10, receiving data from the temperature sensor, the pressure sensor and the position sensor, and initializing the system according to preset parameters;

[0072] S20, controlling the steel fiber dispersing device to start, and evenly dispersing the steel fibers into the mixing drum;

[0073] S30, controlling the concrete conveying device to start and convey a predetermined amount of concrete raw materials into the mixing drum;

[0074] S40, controlling the driving device to start, driving the mixing drum and the mixing shaft to rotate, and fully mixing the concrete and the steel fibers;

[0075] S50, monitoring the temperature of concrete in the mixing drum, and when the temperature reaches a preset value, controlling the heating device of the dough collecting roller to start, heating the dough collecting roller to a predetermined temperature;

[0076] S60, controlling the inclination of the mixing drum to slowly pour the evenly mixed high-viscosity concrete onto the finishing roller;

[0077] S70, control the hydraulic pump station to start, drive the hydraulic cylinder to drive the finishing plate to descend, and compact the concrete on the finishing roller;

[0078] S80, according to the data fed back by the position sensor, adjust the pressure and position of the finishing plate to ensure that the concrete surface is flat;

[0079] S90, when the dough collecting process is completed, the cleaning device is controlled to start, and the mixing drum, the mixing shaft and the dough collecting roller are cleaned to complete a working cycle.

[0080] The system provided by the invention specifically includes:

[0081] 1. Base The base is made of steel rectangular flat plate with a size of 2000mm×1500mm×20mm. This thickness can provide sufficient bearing capacity and ensure the stability of the entire system. The base material is made of high-quality carbon steel, which has been processed by pickling, sandblasting, hot-dip galvanizing and other processes and has good corrosion resistance and wear resistance. There are fixing holes at the four corners of the base to firmly install the entire system on the ground.

[0082] 2. Support frame The support frame consists of three parts: left column, right column and top beam. The left and right columns are made of φ150mm×10mm thick-walled seamless steel pipes, and the surface is sprayed with anti-corrosion paint. The columns and the base are fixed by flange welding. The top beam is made of φ120mm×8mm seamless steel pipes, and the two ends are welded to the top of the left and right columns to form a rigid space frame structure. This support frame design is not only reliable and durable, but also can effectively transmit various external loads to ensure the overall stability of the entire system.

[0083] 3. Mixing drum The mixing drum adopts a thick-walled cylindrical structure of φ1200mm×2000mm, with a wall thickness of 10mm and is made of 304 stainless steel. This size can accommodate enough concrete raw materials and provide good flow space during the mixing process. The φ30mm bearing seats are welded at both ends of the drum, which are connected to the bearing seats of the left and right columns through rolling bearings to realize the rotation of the drum.

[0084] 16 mixing blades with a thickness of 8mm and a length of 500mm are welded along the axial direction of the inner wall of the cylinder, and the blades are distributed in a spiral shape. This design can produce a good mixing airflow to ensure the full mixing of concrete and steel fiber. At the same time, there is also a φ80mm mixing shaft inside the cylinder, and both ends are installed on the left and right end covers through bearing seats. 16 mixing arms with a thickness of 12mm and a length of 800mm are welded along the axial direction of the mixing shaft, and the arm length is distributed in a radial shape. The right end of the mixing shaft is connected to the output shaft of the driving device through a coupling to drive the mixing shaft.

[0085] 4. Drive device The drive device adopts a 7.5kW three-phase asynchronous motor with a rated speed of 1450r / min. The motor is installed on the right column, and the output shaft is connected to the coupling at the right end of the mixing drum to drive the mixing drum and the mixing shaft to rotate. The speed of the motor can be steplessly adjusted by the matching frequency converter to meet the mixing requirements under different working conditions.

[0086] 5. Steel fiber dispersion device The steel fiber dispersion device is arranged above the top beam and mainly consists of four parts: storage hopper, spiral conveying pipe, vibrating screen and dispersion plate.

[0087] The storage hopper adopts a φ800mm×1000mm conical structure, with the upper opening as the feed port and the lower opening as the discharge port, and is made of 304 stainless steel. This size can accommodate a sufficient amount of steel fiber raw materials. There are 4 φ20mm lifting ears welded on the outer wall of the hopper for lifting and fixing on the top beam.

[0088] The spiral conveying pipe is made of seamless steel pipe of φ150mm×2000mm, and is equipped with spiral conveying blades of φ120mm×1950mm inside. The blade pitch is 100mm, and the material is high-quality carbon steel. The feeding end of the spiral conveying pipe is connected with the discharge port of the storage hopper, and the discharge end is installed above the vibrating screen. The device can slowly convey the steel fiber raw materials in the storage hopper to the vibrating screen.

[0089] The vibrating screen adopts a rectangular mesh structure of 800mm×600mm, and the mesh aperture is 3mm. The mesh is fixed on the support frame, and the vibrating screen body is driven by a φ50mm eccentric motor with adjustable vibration frequency. The device can filter and disperse the delivered steel fibers.

[0090] The diameter of the dispersion disc is 800mm, the upper surface is 30° conical, and the material is 304 stainless steel. There are 24 φ20mm discharge holes evenly distributed on the edge of the disc. The dispersion disc is installed under the vibrating screen to spray the filtered and dispersed steel fibers into the mixing drum.

[0091] 6. Concrete conveying device The concrete conveying device is arranged above the left column and consists of three parts: hopper, screw pump and conveying pipe.

[0092] The hopper adopts a conical structure of φ800mm×1000mm, made of carbon steel, and sprayed with epoxy resin for corrosion protection. The hopper is fixedly installed on the left column and is used to store concrete raw materials.

[0093] The screw pump adopts 10m 3 / h conveying capacity, power is 4kW. The pump body is made of gray cast iron, and the spiral blades are made of high-quality carbon steel. The feed end of the pump is connected to the discharge port of the hopper, and the discharge end is connected through a DN100 conveying pipe. The pump can convey the concrete raw materials in the hopper to the inside of the mixing drum.

[0094] The delivery pipe is a φ100mm×3000mm thick-walled PVC pipe, with a φ80mm nozzle at the end of the pipe. The nozzle outlet faces the center of the mixing drum and is used to accurately spray the concrete raw materials into the mixing area.

[0095] 7. The dough collecting roller is a hollow cylindrical structure with an outer diameter of 500mm, an inner diameter of 420mm, a length of 1500mm, a wall thickness of 40mm, and is made of 45# carbon steel. Both ends of the roller are installed on the left and right columns through bearing seats and can rotate freely.

[0096] There are 24 spiral grooves evenly distributed along the circumference of the roller surface, with a groove depth of 5mm and a groove width of 20mm. This special surface texture can compact the concrete surface during the finishing process and improve the surface flatness.

[0097] A heating device is installed inside the roller body, including 8 φ10mm stainless steel heating wires and 2 PT100 temperature sensors. The heating wires are wound around the inner wall of the roller body and can heat the roller body to about 150°C. The temperature sensor is installed on the inner surface of the roller body to monitor the roller surface temperature in real time and provide feedback for heating control. At the same time, a φ20mm water inlet and outlet are provided at one end of the roller body, which are connected to the external water source and drainage pipeline through a rotating joint, so that the heating device can be cooled and controlled.

[0098] 8. The dough collecting plate adopts a rectangular steel plate structure of 800mm×1500mm×50mm, made of 45# carbon steel. There are 24 triangular embossings evenly distributed on the bottom of the plate, which match the spiral grooves on the surface of the dough collecting roller.

[0099] The pressing plate is installed above the top beam through three φ80mm hydraulic cylinders. The cylinder body of the hydraulic cylinder is fixed on the top beam, and the end of the piston rod is hinged to the back of the pressing plate. The three hydraulic cylinders are arranged in a 120° triangle distribution, which can reliably support and drive the lifting and lowering movement of the pressing plate.

[0100] The hydraulic cylinder has a working pressure of up to 15MPa and is connected to the hydraulic pump station installed on the base through a hydraulic pipeline. The hydraulic pump station includes a 2.2kW motor-driven plunger pump that can provide the required pressure oil source for the hydraulic cylinder. The lifting position of the pressure plate is monitored by feedback from the position sensor installed on the pressure plate.

[0101] 9. Cleaning device The cleaning device is arranged on the base and consists of three parts: a water tank, a high-pressure water pump and a water spray pipe.

[0102] The water tank is a 1000L steel rectangular tank with dimensions of 1000mm×800mm×1250mm, made of carbon steel, and sprayed with epoxy resin. The water tank is fixedly installed on the upper part of the base and connected to the water inlet of the high-pressure water pump through a pipe.

[0103] The high-pressure water pump is driven by a three-phase motor with a power of 7.5kW, with a maximum water outlet pressure of 15MPa and a water outlet of 30L / min. The pump body is made of stainless steel and the pump blades are made of wear-resistant ceramics. The water outlet of the water pump is connected to the water spray pipe through a DN50 pipe.

[0104] The water spray pipe is 6000mm long, 50mm in diameter, and made of stainless steel. There are 48 nozzles with a diameter of 10mm evenly distributed along the length of the mixing drum, and the angle of the nozzles is facing the inner wall of the mixing drum. The cleaning device can perform high-pressure water washing on key components such as the inner wall of the mixing drum, the mixing shaft, and the dough collecting roller to ensure the cleanliness of the equipment.

[0105] In addition, the system also includes a control box, which is installed on the base and has a controller inside. The controller is electrically connected to the drive device, steel fiber dispersing device, concrete conveying device, surface roller heating device, hydraulic pump station and high-pressure water pump. It is also connected with temperature sensors, pressure sensors and position sensors, etc., to monitor the working status of various components of the system.

[0106] The following describes the specific workflow of the system:

[0107] Step S10: Receive sensor data and initialize the system

[0108] This step mainly includes the following sub-steps:

[0109] S10-1: Receive the signal from the temperature sensor and obtain the initial temperature T0 of the concrete in the mixing drum. The temperature sensor is installed on the inner wall of the mixing drum and can monitor the temperature change of the concrete in real time.

[0110] S10-2: Receive the signal of the pressure sensor and obtain the initial pressure P0 of the hydraulic cylinder. The pressure sensor is installed on the hydraulic cylinder and is used to detect the working pressure of the hydraulic system.

[0111] S10-3: Receive the signal of the position sensor and obtain the initial position of the dough collecting plate. The position sensor is installed on the dough collecting plate and can feedback the lifting position information of the plate.

[0112] S10-4: Input the acquired temperature T0, pressure P0 and position information into the initialization program of the controller, and initialize the system according to the preset process parameters. This lays the foundation for subsequent process control.

[0113] Through this step, the system can grasp the initial working conditions of concrete, hydraulics and finishing mechanisms, providing necessary reference basis for subsequent process control.

[0114] Step S20: Start the steel fiber dispersing device

[0115] This step mainly includes the following sub-steps:

[0116] S20-1: The controller sends a start signal to the steel fiber storage hopper to start discharging the material from the storage hopper. The discharge port at the bottom of the storage hopper opens to slowly convey the stored steel fiber raw material to the feed end of the spiral conveying pipe.

[0117] S20-2: The controller simultaneously sends a start signal to the driving motor of the spiral conveying pipe, driving the spiral blades to rotate, thereby driving the steel fibers to be transported along the pipeline to the top of the vibrating screen.

[0118] S20-3: The controller also sends a start signal to the eccentric motor of the vibrating screen, causing the vibrating screen to generate high-frequency vibration. Under the action of vibration, the steel fibers are fully dispersed and broken, and fall from the screen to the top of the dispersion plate.

[0119] S20-4: The controller finally sends a start signal to the motor of the dispersion disk, driving the dispersion disk to rotate at high speed. Under the action of centrifugal force, the dispersed steel fibers are sprayed from the discharge holes on the side of the disk into the inside of the mixing drum, achieving uniform dispersion of the concrete.

[0120] Through this step, the system can effectively disperse the pre-stored steel fibers into the concrete in the mixing drum through a controllable conveying, dispersion and spraying process, preparing for subsequent mixing and finishing.

[0121] Step S30: Start the concrete conveying device

[0122] This step mainly includes the following sub-steps:

[0123] S30-1: The controller sends a start signal to the hopper, opens the discharge port at the bottom of the hopper, and delivers a predetermined amount of concrete raw materials to the feed end of the screw pump.

[0124] S30-2: The controller simultaneously sends a start signal to the motor of the screw pump, driving the screw blades to rotate at high speed, and transporting the concrete raw materials in the hopper to the conveying pipe.

[0125] S30-3: The controller finally sends an opening signal to the nozzle at the outlet of the conveying pipe, and the concrete raw materials are sprayed into the central area inside the mixing drum under high pressure.

[0126] Through this step, the system can accurately deliver the required concrete raw materials into the mixing drum, preparing for subsequent mixing and finishing.

[0127] Step S40: Start stirring process

[0128] This step mainly includes the following sub-steps:

[0129] S40-1: The controller sends a start signal to the motor of the driving device, driving the mixing drum and the mixing shaft to rotate at a certain speed ω. The value of ω can be obtained by real-time detection of the speed sensor of the driving device.

[0130] S40-2: Under the coordinated rotation of the mixing drum and the mixing shaft, the concrete and steel fibers in the drum are fully stirred to achieve complete mixing of the materials.

[0131] S40-3: The system monitors the density ρ and dynamic viscosity μ of the concrete in the mixing drum in real time. The density ρ can be measured by sampling and weighing, and the viscosity μ can be measured by a rotational viscometer.

[0132] S40-4: According to the stirring efficiency formula Combined with the real-time acquired ω, R, ρ and μ data, the current stirring efficiency E is calculated. m Among them, k1, k2, k3 are unknown coefficients, and ε is the error term.

[0133] S40-5: If E m If the preset ideal value is not reached, the system will automatically adjust the speed of the mixing drum until E m Meet the requirements.

[0134] Through this step, the system can ensure that the concrete and steel fibers are fully and evenly mixed, creating good prerequisites for subsequent forming and finishing.

[0135] Step S50: heating the dough collecting roller

[0136] This step mainly includes the following sub-steps:

[0137] S50-1: The controller monitors the temperature T(t) of the concrete in the mixing drum in real time, which can be estimated by the following temperature prediction model:

[0138]

[0139] Among them, Q h is the hydration heat release rate; m c is the mass of concrete; c p is the specific heat of concrete; τ is the thermal time constant; A is the ambient temperature fluctuation amplitude; φ is the phase angle; t is the time; ε is the error term.

[0140] S50-2: Once it is detected that the concrete temperature T(t) reaches the preset finishing temperature requirement, the controller immediately sends a start signal to the heating device of the finishing roller.

[0141] S50-3: The heating wire in the heating device starts to heat up and transfers the heat to the surface of the dough collecting roller by radiation and conduction, causing it to quickly heat up to a predetermined temperature.

[0142] S50-4: At the same time, the controller will also start the cooling water circulation system inside the dough collecting roller, and transport cooling water to the inside of the roller body through the water inlet and outlet, so as to accurately control the heating process and ensure the stability of the roller surface temperature.

[0143] Through this step, the system can actively adjust the temperature of the finishing roller according to the real-time monitoring results of the concrete temperature, ensure the temperature matching of the concrete and the finishing roller during the finishing process, and improve the molding quality.

[0144] Step S60: Tilt the mixing drum

[0145] This step mainly includes the following sub-steps:

[0146] S60-1: The controller sends a control signal to drive the mixing drum shaft to gradually tilt, so that the drum tilt angle reaches about 10°.

[0147] S60-2: Under the action of gravity, the fully mixed and uniform high-viscosity concrete slowly flows from the center of the mixing drum to the discharge port on one side.

[0148] S60-3: The concrete maintains good continuity and fluidity during the flow process, preparing for the subsequent finishing process.

[0149] Through this step, the system can smoothly transport the mixed concrete to the top of the finishing roller, avoiding flow interruption or instability during the finishing process and ensuring the finishing quality.

[0150] Step S70: Start surface compaction

[0151] This step mainly includes the following sub-steps:

[0152] S70-1: The controller sends a start signal to the hydraulic pump station, driving the hydraulic cylinder to slowly descend, driving the surface pressing plate to move toward the concrete surface.

[0153] S70-2: The pressure P(t) of the hydraulic cylinder can be adjusted by the following PID control model:

[0154]

[0155] Where P0 is the initial pressure, K p ,K i ,K d is the control parameter, e(t) is the pressure error, Pset is the set pressure, and ε is the error term.

[0156] S70-3: The pressing plate repeatedly compacts the surface of the concrete flowing out of the mixing drum under controlled pressure to gradually shape it.

[0157] S70-4: The embossing on the bottom of the pressing plate cooperates with the spiral grooves on the surface of the finishing roller to further improve the flatness of the concrete surface.

[0158] Through this step, the system can accurately control the finishing pressure to ensure that the concrete surface is flat and smooth and meets the use requirements.

[0159] Step S80: Optimizing the quality of the finished product

[0160] This step mainly includes the following sub-steps:

[0161] S80-1: The controller monitors the position of the dough collecting plate in real time and adjusts the driving force of the hydraulic cylinder according to the feedback signal of the position sensor to keep the plate in the best working position at all times.

[0162] S80-2: At the same time, the system will also make real-time evaluation and optimization adjustments based on the flatness F of the concrete surface:

[0163]

[0164] Where N is the number of measurement points, h i is the height of the ith measuring point, h is the average height, β and γ are weight coefficients, and ε is the error term.

[0165] S80-3: If the F value does not reach the preset ideal range, the controller will adjust the pressure of the hydraulic cylinder and the position of the finishing plate again until the concrete surface flatness meets the requirements.

[0166] Through this step, the system can monitor and accurately control the finishing process in real time to ensure that the concrete surface finally reaches the ideal smooth and clean state.

[0167] Step S90: Cleaning equipment

[0168] This step mainly includes the following sub-steps:

[0169] S90-1: After detecting that the dough collecting process is completed, the controller sends a start signal to the high-pressure water pump of the cleaning device.

[0170] S90-2: The high-pressure water pump starts working, pressurizing the cleaning water in the water tank to about 15MPa, and spraying it onto the inner wall of the mixing drum, the mixing shaft and the surface of the dough collecting roller through the water spray pipe.

[0171] S90-3: Under the action of high-pressure water flushing, the concrete residues attached to the surface of these key components are thoroughly cleaned.

[0172] S90-4: After cleaning, the system dries all components and prepares for the next working cycle.

[0173] Through this step, the system can automatically clean the equipment regularly to ensure that all components remain in good working condition, extend the service life of the equipment and improve production efficiency.

[0174] In summary, the high-viscosity concrete finishing system with steel fibers can achieve functions such as sufficient mixing and dispersion of concrete, precise finishing and shaping, and regular cleaning and maintenance of equipment through a series of carefully designed process steps such as S10-S90. Each step adopts corresponding measurement models, control algorithms and automation technologies according to actual process requirements to ensure that the entire production process is efficient, stable and controllable. This systematic design provides strong support for the large-scale production of high-viscosity concrete products.

[0175] Example

[0176] The high-viscosity concrete finishing system with steel fibers proposed in the present invention has been successfully applied to the foundation engineering construction of a large-scale comprehensive building complex. The building complex is located in the coastal area and consists of 5 50-story office buildings and 1 30-story hotel building, with a total construction area of ​​1.5 million square meters. In order to ensure the safety and durability of the building foundation, the engineering design unit requires the use of high-viscosity steel fiber reinforced concrete with excellent adhesion and crack resistance.

[0177] According to the specific requirements of the project, the construction team developed and produced a customized high-viscosity concrete finishing system with steel fibers, and put it into the project site for application verification. During the four-month practical application process, the system played a significant technical advantage, not only ensuring the excellent performance of high-viscosity concrete products, but also greatly improving production efficiency, providing strong support for engineering construction.

[0178] The specific situation of the system in practical application is summarized as follows:

[0179] 1. System parameter design According to the high viscosity concrete performance indicators required by the project, the construction team carried out targeted parameter design for each functional module of the system, as follows:

[0180] Table 1 Main parameters of the system design indicators

[0181]

[0182]

[0183] As can be seen from the table above, the dimensions and performance parameters of the main components of the system are reasonably designed and matched according to the characteristics of the high-viscosity concrete products and production process requirements required by the project. For example, the diameter and length of the mixing drum can meet the mixing needs of large quantities of concrete, and the power of the drive motor is also increased accordingly to ensure that the mixing shaft can drive the drum and the internal mixing blades to operate efficiently. At the same time, the working pressure of the hydraulic cylinder and the water outlet pressure of the water pump are also optimized according to the molding characteristics of high-viscosity concrete to achieve the best compaction effect of the surface roller and the pressure plate.

[0184] 2. Process parameter optimization In addition to the optimization design of hardware equipment parameters, the construction team also conducted in-depth research and debugging on the key process parameters of the system based on the process characteristics of the high-viscosity concrete products. Mainly including:

[0185] (1) Steel fiber dispersion effect Based on the mix ratio of high viscosity concrete used in this project, the construction team determined its density ρ to be 2450 kg / m 3 , the dynamic viscosity μ is 12Pa·s. The length L of the pre-added steel fiber is 30mm and the diameter d is 0.5mm.

[0186] In order to ensure good dispersion of steel fibers in concrete, the construction team adjusted the vibration frequency of the vibrating screen and the speed of the dispersion disc, and finally determined the optimal process parameters as follows:

[0187] Vibrating screen frequency: 45Hz Dispersion disk speed: 1200rpm

[0188] Under this process parameter, the construction team sampled and tested the dispersion of steel fibers in the concrete in the mixing drum. The results showed that the fiber distribution was relatively uniform, with an average fiber content of 60kg / m 3 , the segregation rate is less than 5%, meeting the design requirements.

[0189] (2) Stirring efficiency optimization According to the above stirring efficiency formula Combined with the actual measured ρ, μ and ω data, the construction team determined the optimal parameter combination of k1=0.18, k2=0.32, k3=0.48 through experimental fitting method.

[0190] Under this parameter setting, the system can achieve a stirring efficiency E m ≥85% stable operation meets the requirements of concrete mixing quality. The construction team regularly samples and tests the mechanical properties of concrete in the mixing drum. The results show that the compressive strength reaches 42MPa, which is consistent with the design indicators.

[0191] (3) The finishing temperature is controlled according to the aforementioned temperature prediction model The construction team determined that the initial temperature T0 of the high viscosity concrete was 25°C and the hydration heat release rate Q h 220 J / s, mass m c is 1800kg, specific heat capacity c p is 920J / (kg·℃), the thermal time constant τ is 3600s, the ambient temperature fluctuation amplitude A is 5℃, and the phase angle φ is π / 4.

[0192] According to the model, the temperature of the concrete will reach about 35°C after 30 minutes of mixing. Therefore, the construction team set the target heating temperature of the finishing roller to 40°C to ensure that the surface temperature of the concrete can be kept within the ideal range during the finishing process. In actual operation, the surface temperature of the finishing roller can be stabilized between 39-41°C, which matches the concrete temperature well.

[0193] (4) Compacting pressure control In order to accurately control the compacting pressure of the finishing plate, the construction team adopted a PID closed-loop control algorithm. According to the aforementioned pressure control model P(t) = P0 + K p e(t)+ After debugging and optimization, K p =0.6, K i =0.12 and K d = control parameter of 0.03.

[0194] Under this parameter, the system can adjust the initial pressure P0 to the set value Pset = 12MPa, and can track the pressure error e(t) in real time, quickly eliminate pressure fluctuations, and ensure that the pressure applied by the finishing plate on the concrete surface is stable and controllable. By collecting pressure sensor data, the construction team found that the stability of the compaction pressure is better than ±0.3MPa, which meets the requirements for high-viscosity concrete molding.

[0195] (5) Surface flatness evaluation Based on the above surface flatness evaluation model The construction team used a laser scanner to measure the concrete surface after finishing and forming. The number of sampling points was N = 25. After multiple test fittings, the optimal weight parameters of β = 0.4 and γ = 0.6 were determined.

[0196] The measurement results show that the surface flatness index F of the high-viscosity concrete product is 2.1mm on average, meeting the ±3mm tolerance requirement of the engineering design. The construction team regularly inspects the surface quality and finds that the incidence of surface defects such as corrugation and roughness is less than 3%, which is far lower than the industry average.

[0197] Through precise optimization of the above process parameters, the construction team ensured the stability and control of the high-viscosity concrete products with steel fibers in various process links such as mixing and finishing, laying a good foundation for subsequent construction applications.

[0198] 3. System operation status Since it was put into use, this high-viscosity concrete finishing system has provided production services for the foundation construction of this large building complex for nearly 4 months. During the actual operation, all components of the system operated stably, the product quality continued to meet the project requirements, and the production efficiency was significantly improved. The specific situation is as follows:

[0199] (1) Production efficiency The system is designed to produce 10m per hour. 3 After actual operation tracking, the system produces an average of 9.6m per hour. 3 , the capacity utilization rate reached 96%, which is much higher than the level of traditional mixing plants.

[0200] The construction team compared the production method using this system with the traditional method of using a mixer truck for transportation and manual finishing, and found that the comprehensive production cost per unit product of the former was reduced by about 25%, greatly improving the economic benefits. The main reason is that the system achieves efficient dispersion of steel fibers, precise finishing of concrete, and automatic cleaning of equipment, which greatly shortens the production cycle and reduces labor costs.

[0201] (2) Product quality During the four-month practical application, the construction team regularly sampled and tested the various performance indicators of the high-viscosity concrete products. The results showed that they could stably meet the design requirements. The specific data are as follows:

[0202] Table 2 Performance indexes of high viscosity concrete products

[0203] As can be seen from the table above, the various performance indicators of the high-viscosity concrete product not only meet the engineering design requirements, but also exceed the design values ​​for some indicators such as tensile strength and durability. This is mainly due to the efficient dispersion of steel fibers, precise shaping of concrete, and effective implementation of equipment cleaning measures by the system of the present invention.

[0204] (3) Equipment operation status Since the system was put into use, all components have been running stably, and the equipment failure rate is less than 3%, which is much better than similar mechanical equipment. The construction team regularly uses high-pressure water to clean key components such as the inner wall of the mixing drum, the mixing shaft and the finishing roller, which effectively avoids the accumulation of concrete residues and prolongs the service life of the equipment.

[0205] At the same time, the system has a high degree of automation, and the controller can monitor and accurately control various process parameters such as temperature, pressure, position, etc. in real time to ensure the stability and controllability of the entire production process. The construction team regularly checks the sensors and actuators of the system and finds that they are in good operating condition with a calibration deviation of less than 5%.

[0206] In summary, this high-viscosity concrete finishing system with steel fibers has fully demonstrated its technical advantages in steel fiber dispersion, concrete forming and equipment cleaning during the four-month practical application. It not only ensured that the product quality met the design indicators, but also greatly improved the production efficiency, providing strong support for the foundation construction of this large-scale building complex.

[0207] Specifically, the principle of the present invention is:

[0208] 1. Efficient dispersion mechanism of steel fiber In order to solve the problem of difficult dispersion of steel fiber in high viscosity concrete, this system adopts a special steel fiber dispersion device to achieve efficient dispersion of fiber. Among them, the combination of storage hopper, spiral conveyor pipe and vibrating screen can slowly and continuously convey and preliminarily disperse the pre-dosed steel fiber raw materials, avoiding the entanglement and agglomeration of fibers during the transportation process. The dispersion disc set up later can evenly spray the screened steel fiber into the mixing drum through the centrifugal force generated by high-speed rotation, ensuring the full dispersion and distribution of the fiber in the concrete matrix. This dispersion mechanism not only improves the utilization rate of steel fiber in concrete, but also lays a good foundation for the subsequent mixing and molding process.

[0209] 2. Precise finishing mechanism for high-viscosity concrete To address the problem that high-viscosity concrete is difficult to form naturally, this system uses a finishing mechanism that integrates heating and compaction, including a finishing roller and a finishing plate. The finishing roller is equipped with an electric heating wire heating device, which can heat the roller body to about 150°C. When it comes into contact with the high-temperature concrete surface, it produces a good interfacial rheological effect, improving the fluidity and forming performance of the concrete. At the same time, the finishing plate is driven by a precisely controlled hydraulic cylinder to apply a certain pressure to the concrete surface on the roller surface, so that it is gradually formed during the compaction process. The embossing on the bottom of the plate matches the spiral groove on the roller surface, further optimizing the flatness of the concrete surface.

[0210] This heating-compacting finishing mechanism can effectively overcome the problem that high-viscosity concrete is difficult to form naturally, ensuring that the surface of the final product is smooth and flat, meeting the requirements of use. At the same time, through real-time monitoring and feedback control of finishing parameters such as temperature and pressure, the finishing quality is further optimized and the controllability of the production process is improved.

[0211] 3. Intelligent control logic of the system The system of the present invention uses a centralized controller to intelligently manage each functional module, realizing precise coordinated control of process links such as steel fiber dispersion, concrete mixing, surface forming, and equipment cleaning. The controller not only receives process parameter feedback signals from multiple sensors such as temperature, pressure, and position, but also monitors and optimizes these parameters in real time according to the preset algorithm model to ensure the stable operation of each process link.

[0212] For example, during the mixing process, the controller can Automatically adjust the speed of the stirring shaft ω to make the stirring efficiency E m The ideal value is achieved to ensure that the concrete and steel fibers are fully mixed. During the finishing process, the controller also accurately controls the compaction pressure and the position of the pressing plate according to the pressure PID model of the hydraulic cylinder and the surface flatness evaluation model to optimize the molding quality of the concrete.

[0213] This intelligent management mechanism based on closed-loop feedback control not only improves the automation level of the production process, but also greatly improves the consistency and reliability of product quality, laying a solid foundation for the large-scale production of high-viscosity concrete products.

[0214] In summary, the high-viscosity concrete finishing system with steel fibers proposed in the present invention fully considers the key technical difficulties in the preparation and molding of high-viscosity concrete, and effectively solves the pain points that cannot be met by existing technologies through innovative designs such as a dedicated steel fiber dispersion device, a heating-compacting finishing mechanism, and intelligent process control, providing an advanced and reliable process technology solution for the future production of high-performance concrete products.

[0215] The above is only a specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present invention, which should be included in the protection scope of the present invention. Therefore, the protection scope of the present invention should be based on the protection scope of the claims.

Claims

1. A high viscosity concrete finishing system with steel fiber, characterized in that: include: A base, a support frame, a mixing drum, a driving device, a steel fiber dispersing device, a concrete conveying device, a dough collecting roller and a dough collecting pressing plate; the base is in the shape of a rectangular flat plate, and the support frame is fixedly installed on the base; the support frame includes a left column, a right column and a top beam, the left column and the right column are vertically arranged on the base, and the top beam horizontally connects the top ends of the left column and the right column; the mixing drum is cylindrical, and the two ends of the mixing drum are rotatably installed on the left column and the right column respectively through bearing seats; the driving device is installed on the right column, and the output shaft of the driving device is connected to the mixing drum The right end of the mixing drum is transmission connected; the steel fiber dispersing device is installed on the top beam, and the discharge port of the steel fiber dispersing device is aligned with the upper opening of the mixing drum; the concrete conveying device is installed on the left column, and the discharge pipe of the concrete conveying device extends into the mixing drum; the dough collecting roller is a hollow cylindrical shape, and the two ends of the dough collecting roller are rotatably mounted on the left column and the right column respectively through bearings, and the dough collecting roller is located directly below the mixing drum; the dough collecting pressure plate is a long strip, and the dough collecting pressure plate is installed on the top beam through multiple hydraulic cylinders, and the dough collecting pressure plate is located directly above the dough collecting roller.

2. A high viscosity concrete finishing system with steel fibers according to claim 1, characterized in that: A plurality of stirring blades are fixedly installed along the axial direction on the inner wall of the stirring drum, and the stirring blades are distributed in a spiral shape; a stirring shaft is also coaxially provided inside the stirring drum, and both ends of the stirring shaft are rotatably installed on the left end cover and the right end cover of the stirring drum through bearing seats respectively; a plurality of stirring arms are fixedly installed along the axial direction on the stirring shaft, and the stirring arms are distributed in a radial shape; the right end of the stirring shaft is connected to the output shaft of the driving device through a coupling.

3. A high viscosity concrete finishing system with steel fibers according to claim 2, characterized in that: The steel fiber dispersing device comprises a storage hopper, a spiral conveying pipe, a vibrating screen and a dispersing disk; the storage hopper is funnel-shaped and fixedly mounted on a top beam; the feed end of the spiral conveying pipe is connected to the discharge port of the storage hopper, and a spiral conveying blade is arranged in the spiral conveying pipe; the vibrating screen is installed below the discharge end of the spiral conveying pipe, and a plurality of sieve holes are arranged on the vibrating screen; the dispersing disk is installed below the vibrating screen, and is disc-shaped, with a conical upper surface, and a plurality of evenly distributed discharge ports are arranged on the edge of the dispersing disk.

4. A high viscosity concrete finishing system with steel fibers according to claim 3, characterized in that: The concrete conveying device comprises a hopper, a screw pump and a conveying pipe; the hopper is funnel-shaped and fixedly mounted on a left column; the screw pump is mounted below the hopper, and a feed port of the screw pump is connected to a discharge port of the hopper; one end of the conveying pipe is connected to the discharge port of the screw pump, and the other end of the conveying pipe extends into a mixing drum, and a nozzle is provided at the end of the conveying pipe.

5. A high viscosity concrete finishing system with steel fibers according to claim 4, characterized in that: The surface of the dough collecting roller is provided with a plurality of evenly distributed grooves, which are arranged in a spiral shape; a heating device is provided inside the dough collecting roller, and the heating device includes an electric heating wire and a temperature sensor; a water inlet and a water outlet are provided at one end of the dough collecting roller, and the water inlet and the water outlet are respectively connected to an external water source and a drain pipe through a rotating joint.

6. A high viscosity concrete finishing system with steel fibers according to claim 5, characterized in that: The bottom surface of the dough collecting pressure plate is provided with a plurality of evenly distributed embossings, which match with the grooves on the surface of the dough collecting roller; the dough collecting pressure plate is connected to the top beam through at least three hydraulic cylinders, the piston rod ends of the hydraulic cylinders are hinged to the dough collecting pressure plate, and the cylinder bodies of the hydraulic cylinders are fixedly connected to the top beam; the hydraulic cylinders are connected to the hydraulic pump station through hydraulic pipelines, and the hydraulic pump station is installed on a base.

7. A high viscosity concrete finishing system with steel fibers according to claim 6, characterized in that: It also includes a cleaning device, which includes a water tank, a high-pressure water pump and a water spray pipe; the water tank is fixedly installed on the base, and the water tank is connected to the water inlet of the high-pressure water pump through a pipeline; the high-pressure water pump is installed on the base, and the water outlet of the high-pressure water pump is connected to the water spray pipe through a pipeline; the water spray pipe is arranged along the length direction of the mixing drum, and a plurality of nozzles are evenly distributed on the water spray pipe, and the nozzles face the inner wall of the mixing drum.

8. The high viscosity concrete finishing system with steel fiber according to claim 1, characterized in that: It also includes a control box, which is installed on the base; a controller is arranged in the control box, and the controller is electrically connected to the driving device, the steel fiber dispersing device, the concrete conveying device, the heating device of the dough roller, the hydraulic pump station and the high-pressure water pump.

9. A high viscosity concrete finishing system with steel fibers according to claim 8, characterized in that: It also includes multiple sensors, including a temperature sensor, a pressure sensor and a position sensor; the temperature sensor is installed on the mixing drum and the dough roller, and is used to detect the temperature of the concrete in the mixing drum and the surface temperature of the dough roller; the pressure sensor is installed on the hydraulic cylinder, and is used to detect the working pressure of the hydraulic cylinder; the position sensor is installed on the dough pressing plate, and is used to detect the position of the dough pressing plate; the sensors are all electrically connected to the controller.

10. The high viscosity concrete finishing system with steel fiber according to claim 8, characterized in that: The controller is provided with a concrete finishing control module, which is used to control the steel fiber dispersion, concrete mixing and finishing process; the concrete finishing control module performs the following steps: S10, receiving data from the temperature sensor, the pressure sensor and the position sensor, and initializing the system according to preset parameters; S20, controlling the steel fiber dispersing device to start, and evenly dispersing the steel fibers into the mixing drum; S30, controlling the concrete conveying device to start and convey a predetermined amount of concrete raw materials into the mixing drum; S40, controlling the driving device to start, driving the mixing drum and the mixing shaft to rotate, and fully mixing the concrete and the steel fibers; S50, monitoring the temperature of concrete in the mixing drum, and when the temperature reaches a preset value, controlling the heating device of the dough collecting roller to start, heating the dough collecting roller to a predetermined temperature; S60, controlling the inclination of the mixing drum to slowly pour the evenly mixed high-viscosity concrete onto the finishing roller; S70, control the hydraulic pump station to start, drive the hydraulic cylinder to drive the finishing plate to descend, and compact the concrete on the finishing roller; S80, according to the data fed back by the position sensor, adjust the pressure and position of the finishing plate to ensure that the concrete surface is flat; S90, when the dough collecting process is completed, the cleaning device is controlled to start, and the mixing drum, the mixing shaft and the dough collecting roller are cleaned to complete a working cycle.

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