A high viscosity concrete finishing system with steel fibers

Abstract

The application provides a high-viscosity concrete finishing system with steel fibers, and belongs to the technical field of concrete finishing. The high-viscosity concrete finishing system with steel fibers comprises a base, a support frame, a stirring drum, a driving device, a steel fiber dispersing device, a concrete conveying device, a finishing roller and a finishing pressure 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 comprises left and right vertical columns and a top beam. The left and right vertical columns are vertically arranged on the base, and the top beam is horizontally connected to the top ends of the left and right vertical columns. The stirring drum is in the shape of a cylinder, and the two ends of the stirring drum are rotatably installed on the left and right vertical columns through bearing seats. The driving device is installed on the right vertical column, and the output shaft of the driving device is in transmission connection with the right end of the stirring drum. The application can solve the problem that the existing stirring equipment cannot completely disperse steel fibers.

Description

Technical Field

[0001] This invention belongs to the field of concrete finishing technology, and more specifically, relates to a high-viscosity concrete finishing system with steel fibers. Background Technology

[0002] In recent years, due to accelerated urbanization and infrastructure construction, the demand for high-performance concrete products in the construction and infrastructure sectors has been increasing. Typically, high-viscosity concrete requires the addition of large amounts of fly ash, mineral admixtures, or chemical additives during its preparation to enhance its cohesiveness and flowability. However, the greater the amount of these additives added, the more complex the internal pore structure of the concrete becomes, making it prone to segregation and other problems, severely affecting the concrete's workability and final mechanical properties. To address this issue, novel concrete mix design and construction techniques have gradually attracted industry attention.

[0003] Against this backdrop, incorporating steel fibers into high-viscosity concrete can not only improve the tensile strength and toughness of the concrete, but also significantly enhance its crack resistance. Achieving uniform dispersion of steel fibers in high-viscosity concrete has become one of the key factors affecting the quality of this type of concrete product.

[0004] Currently, in the preparation of steel fiber reinforced high-viscosity concrete, the common practice is to mix the steel fibers with the concrete raw materials together in a mixing plant or mixer truck. However, due to the poor fluidity of high-viscosity concrete and the large fiber length, it is difficult to achieve complete dispersion of the steel fibers in traditional mixing equipment, easily leading to clumping or uneven distribution, thus reducing the overall performance of the concrete. Therefore, there is an urgent need to develop a specialized steel fiber dispersion device that can efficiently and uniformly disperse the steel fibers during concrete mixing, laying the foundation for subsequent molding and finishing processes.

[0005] On the other hand, there are still some technical challenges to be addressed in the molding process of high-viscosity concrete products. First, due to the poor fluidity of high-viscosity concrete, it is difficult to mold naturally without any external force, requiring specialized finishing equipment for roller pressing. However, most existing concrete finishing equipment is designed for concrete of conventional strength and viscosity, and cannot meet the molding requirements of high-viscosity concrete. Second, due to the complex internal structure of high-viscosity concrete, surface quality problems such as ripples and pitting are easily encountered during the finishing process, affecting the performance of the finished products. Therefore, developing a reliable finishing system for high-viscosity concrete has become an urgent technical challenge for the industry. 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 of existing mixing equipment having difficulty in completely dispersing steel fibers.

[0007] This invention is implemented as follows:

[0008] This invention provides a high-viscosity concrete finishing system with steel fibers, comprising: a base, a support frame, a mixing drum, a drive device, a steel fiber dispersing device, a concrete conveying device, a finishing roller, and a finishing plate; the base is a rectangular flat plate, on which the support frame is fixedly installed; the support frame includes a left column, a right column, and a top beam, the left and right columns being vertically mounted on the base, and the top beam horizontally connecting the top ends of the left and right columns; the mixing drum is cylindrical, with its two ends rotatably mounted on the left and right columns via bearing seats; the drive device is mounted on... On the right column, the output shaft of the drive device is connected to the right end of the mixing drum; the steel fiber dispersing device is installed on the top beam, and the outlet 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 its two ends are rotatably installed on the left and right columns respectively through bearings, with the dough-collecting roller located directly below the mixing drum; the dough-collecting pressure plate is a long strip shape, and the dough-collecting pressure plate is installed on the top beam through multiple hydraulic cylinders, with the dough-collecting pressure plate located directly above the dough-collecting roller.

[0009] The technical effects of the high-viscosity concrete finishing system with steel fibers provided by this invention are as follows: 1. To address the problem of difficult dispersion of steel fibers inside 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 disc, which can effectively disperse the pre-added steel fibers into the concrete in the mixing drum, ensuring the uniform distribution of steel fibers in the concrete matrix and creating good preconditions for subsequent molding and finishing.

[0010] 2. To address the issue that existing concrete finishing equipment cannot meet the molding requirements of high-viscosity concrete, this system designs a finishing mechanism with heating and compaction functions, including a hollow cylindrical finishing roller and a long strip-shaped finishing plate. The finishing roller is equipped with a heating device that preheats the roller to a certain temperature, generating good rheological interaction when in contact with the high-temperature concrete surface, effectively improving the concrete's molding performance. Simultaneously, the finishing plate uses a hydraulic cylinder to precisely control the pressure, uniformly compacting the concrete surface to ensure the final product achieves an ideal smooth and glossy finish.

[0011] 3. This 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 flush key components such as the inner wall of the mixing drum, the mixing shaft, and the dough roller with high-pressure water to keep the equipment clean and hygienic, 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, and compaction pressure, are monitored and precisely controlled in real time by the controller. Simultaneously, it integrates multiple sensors for temperature, pressure, and position, forming a closed-loop control system to ensure a high degree of automation and intelligence throughout the production process, significantly improving the stability and reliability of the process.

[0013] In summary, the high-viscosity concrete finishing system with steel fibers designed in this invention effectively solves the key problems existing in the prior art. It not only ensures the uniform dispersion of steel fibers in concrete, but also enables precise molding of high-viscosity concrete and automated cleaning of equipment, greatly improving the production quality and efficiency of this type of high-performance concrete product, and providing advanced technological support for future infrastructure construction.

[0014] Based on the above technical solution, the high-viscosity concrete finishing system with steel fibers of the present invention can be further improved as follows:

[0015] The stirring cylinder has multiple stirring blades fixedly installed axially on its inner wall, and the stirring blades are arranged in a spiral shape. The stirring cylinder also has a stirring shaft coaxially installed inside, and the two ends of the stirring shaft are rotatably installed on the left end cover and the right end cover of the stirring cylinder through bearing seats, respectively. Multiple stirring arms are fixedly installed axially on the stirring shaft, and the stirring arms are arranged radially. The right end of the stirring shaft is connected to the output shaft of the drive device through a coupling.

[0016] Furthermore, the steel fiber dispersing device includes a storage hopper, a spiral conveying pipe, a vibrating screen, and a dispersing disc; the storage hopper is funnel-shaped and fixedly installed on a top beam; the inlet end of the spiral conveying pipe is connected to the outlet of the storage hopper, and spiral conveying blades are provided inside the spiral conveying pipe; the vibrating screen is installed below the outlet end of the spiral conveying pipe, and multiple screen holes are provided on the vibrating screen; the dispersing disc is installed below the vibrating screen, and the dispersing disc is disc-shaped with a conical upper surface and multiple evenly distributed outlets on the edge of the dispersing disc.

[0017] Furthermore, the concrete conveying device includes a hopper, a screw pump, and a conveying pipe; the hopper is funnel-shaped and fixedly installed on the left column; the screw pump is installed below the hopper, and the inlet of the screw pump is connected to the outlet of the hopper; one end of the conveying pipe is connected to the outlet of the screw pump, and the other end of the conveying pipe extends into the mixing drum, with a nozzle at the end of the conveying pipe.

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

[0019] Furthermore, the bottom surface of the dough-collecting plate is provided with multiple evenly distributed embossed patterns, 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 end of the hydraulic cylinder is hinged to the dough-collecting plate, and the cylinder body of the hydraulic cylinder is fixedly connected to the top beam; the hydraulic cylinder is connected to the hydraulic pump station through hydraulic pipelines, and the hydraulic pump station is installed on the base.

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

[0021] It also includes a control box, which is mounted on the base; the control box contains a controller, which is electrically connected to the drive device, the steel fiber dispersing device, the concrete conveying device, the heating device of the finishing 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 finishing roller to detect the temperature of the concrete inside the mixing drum and the surface temperature of the finishing roller; the pressure sensor is installed on the hydraulic cylinder to detect the working pressure of the hydraulic cylinder; the position sensor is installed on the finishing plate to detect the position of the finishing plate; all sensors are electrically connected to the controller.

[0023] Furthermore, the controller includes a concrete finishing control module, which controls the steel fiber dispersion, concrete mixing, and finishing processes; the concrete finishing control module performs the following steps:

[0024] S10. Receive data from the temperature sensor, pressure sensor, and position sensor, and initialize the system according to preset parameters;

[0025] S20. Start the steel fiber dispersion device to evenly disperse the steel fibers into the mixing drum;

[0026] S30. Control the start of the concrete conveying device to convey the predetermined amount of concrete raw materials into the mixing drum;

[0027] S40. The control drive device is started, which drives the mixing drum and mixing shaft to rotate, and fully mixes the concrete and steel fibers.

[0028] S50. Monitor the concrete temperature inside the mixing drum. When the temperature reaches the preset value, control the heating device of the finishing roller to start and heat the finishing roller to the preset temperature.

[0029] S60. Control the tilt of the mixing drum and slowly pour the well-mixed high-viscosity concrete onto the finishing roller.

[0030] S70. Control the hydraulic pump station to start, drive the hydraulic cylinder to lower the finishing plate, and compact the concrete on the finishing roller.

[0031] S80. Based on 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. After the dough collection process is completed, the cleaning device is started to clean the mixing drum, mixing shaft and dough collection roller, completing one work cycle.

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

[0034]

[0035] In the formula, E m ω 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 / m³). 3 μ is the dynamic viscosity of concrete (Pa·s); k1, k2, k3 are undetermined coefficients; ε is the error term.

[0036] The parameters are obtained as follows: ω is directly measured by the speed sensor of the drive 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 concrete sample of a certain volume; 2. Weigh the sample mass using a precision balance; 3. Calculate the density. Where m is the sample mass (kg) and V is the sample volume (m³). 3 ).

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

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

[0039]

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

[0041] The parameters are obtained as follows: T0 is obtained directly by measuring the temperature using a temperature sensor; Q h Calculated using the following formula: Where q c The potential heat of hydration of cement (J / kg), m cem The mass of cement (kg) The change rate of hydration degree can be obtained experimentally; m c Obtained by weighing; c p Experimentally, the following steps were determined: 1. A concrete sample of known mass was heated to a certain temperature; 2. The amount of heat required for heating was measured; 3. According to the formula... Calculate the specific heat capacity, where Q is the amount of heat (J) and ΔT is the temperature change (°C).

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

[0043]

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

[0045] The parameter acquisition method is as follows: P0 is directly measured by a pressure sensor to obtain K. p ,K i ,K d Determined using the Ziegler-Nichols tuning method: 1. Set K... i and K d Set K to 0, and gradually increase K. p Record K until the system begins to oscillate continuously. p For K uThe oscillation period is T u 2. Calculate according to the formula: 0.6K u ,

[0046] In step S80, the concrete surface smoothness assessment model is specifically represented as follows:

[0047]

[0048] In the formula, F is the surface flatness index; N is the number of measurement points; h i Let be the height (mm) of the i-th measurement point; ε is the average height (mm); β and γ are weighting coefficients; ε is the error term.

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

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

[0051] 1. To address the problem of difficult dispersion of steel fibers inside high-viscosity concrete, this system adopts a specialized steel fiber dispersion device, including a storage hopper, a spiral conveying pipe, a vibrating screen, and a dispersion disc. This device can effectively disperse the pre-added steel fibers into the concrete inside the mixing drum, ensuring the uniform distribution of steel fibers in the concrete matrix and creating favorable conditions for subsequent molding and finishing.

[0052] 2. To address the issue that existing concrete finishing equipment cannot meet the molding requirements of high-viscosity concrete, this system designs a finishing mechanism with heating and compaction functions, including a hollow cylindrical finishing roller and a long strip-shaped finishing plate. The finishing roller is equipped with a heating device that preheats the roller to a certain temperature, generating good rheological interaction when in contact with the high-temperature concrete surface, effectively improving the concrete's molding performance. Simultaneously, the finishing plate uses a hydraulic cylinder to precisely control the pressure, uniformly compacting the concrete surface to ensure the final product achieves an ideal smooth and glossy finish.

[0053] 3. This 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 flush key components such as the inner wall of the mixing drum, the mixing shaft, and the dough roller with high-pressure water to keep the equipment clean and hygienic, 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, and compaction pressure, are monitored and precisely controlled in real time by the controller. Simultaneously, it integrates multiple sensors for temperature, pressure, and position, forming a closed-loop control system to ensure a high degree of automation and intelligence throughout the production process, significantly improving the stability and reliability of the process.

[0055] In summary, the high-viscosity concrete finishing system with steel fibers designed in this invention effectively solves the key problems existing in the prior art. It not only ensures the uniform dispersion of steel fibers in concrete, but also enables precise molding of high-viscosity concrete and automated cleaning of equipment, greatly improving the production quality and efficiency of this type of high-performance concrete product, and providing advanced technological support for future infrastructure construction. Attached Figure Description

[0056] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0057] Figure 1 A schematic diagram of a high-viscosity concrete finishing system with steel fibers;

[0058] The attached diagram lists the components represented by each number as follows:

[0059] 10. Base; 100. Control box; 20. Support frame; 21. Left column; 22. Right column; 23. Top beam; 30. Mixing tank; 31. Mixing blades; 32. Mixing shaft; 33. Mixing arm; 40. Drive unit; 50. Steel fiber dispersion device; 51. Storage hopper; 52. Spiral conveyor pipe; 53. Vibrating screen; 54. Dispersion disc; 60. Concrete conveying device; 61. Hopper; 62. Spiral pump; 63. Conveying pipe; 70. Finishing roller; 71. Groove; 80. Finishing plate; 90. Cleaning device; 91. Water tank; 92. High-pressure water pump; 93. Spray pipe. Detailed Implementation

[0060] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0061] like Figure 1The diagram illustrates an embodiment of a high-viscosity concrete finishing system with steel fibers provided by the present invention. This embodiment includes: a base 10, a support frame 20, a mixing drum 30, a drive device 40, a steel fiber dispersing device 50, a concrete conveying device 60, a finishing roller 70, and a finishing pressure plate 80. The base is a rectangular flat plate, on which the support frame is fixedly installed. The support frame includes a left column 21, a right column 22, and a top beam 23. The left and right columns are vertically mounted on the base, and the top beam horizontally connects the tops of the left and right columns. The mixing drum is cylindrical, with both ends rotatably mounted via bearing seats. The mixing drum is mounted on the left and right columns; the drive unit is mounted on the right column, and the output shaft of the drive unit is connected to the right end of the mixing drum; the steel fiber dispersing device is mounted on the top beam, and the outlet of the steel fiber dispersing device is aligned with the upper opening of the mixing drum; the concrete conveying device is mounted 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 its two ends are rotatably mounted on the left and right columns 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 mounted on the top beam through multiple hydraulic cylinders, and the dough-collecting pressure plate is located directly above the dough-collecting roller.

[0062] In the above technical solution, multiple stirring blades 31 are fixedly installed axially on the inner wall of the stirring drum, and the stirring blades are distributed in a spiral shape; a stirring shaft 32 is also coaxially installed inside the stirring drum, and the two 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; multiple stirring arms 33 are fixedly installed axially on the stirring shaft, and the stirring arms are distributed radially; the right end of the stirring shaft is connected to the output shaft of the drive 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 disc 54; the storage hopper is funnel-shaped and is fixedly installed on the top beam; the inlet end of the spiral conveying pipe is connected to the outlet of the storage hopper, and spiral conveying blades are provided inside the spiral conveying pipe; the vibrating screen is installed below the outlet end of the spiral conveying pipe, and multiple screen holes are provided on the vibrating screen; the dispersion disc is installed below the vibrating screen, and the dispersion disc is disc-shaped, with a conical upper surface and multiple evenly distributed outlets on the edge of the dispersion disc.

[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 is fixedly installed on the left column; the screw pump is installed below the hopper, and the inlet of the screw pump is connected to the outlet of the hopper; one end of the conveying pipe is connected to the outlet of the screw pump, and the other end of the conveying pipe extends into the mixing drum, and the end of the conveying pipe is provided with a nozzle.

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

[0066] Furthermore, in the above technical solution, the bottom surface of the dough-collecting plate is provided with multiple evenly distributed embossed patterns, 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 end of the hydraulic cylinder is hinged to the dough-collecting plate, and the cylinder body of the hydraulic cylinder is fixedly connected to the top beam; the hydraulic cylinder is connected to the hydraulic pump station through hydraulic pipelines, and the hydraulic pump station is installed on the base.

[0067] Furthermore, the above technical solution also includes a cleaning device 90, which includes a water tank 91, a high-pressure water pump 92, and a spray pipe 93. The water tank is fixedly installed on the base and is connected to the inlet of the high-pressure water pump through a pipe. The high-pressure water pump is installed on the base and its outlet is connected to the spray pipe through a pipe. The spray pipe is arranged along the length of the mixing drum and has multiple nozzles evenly distributed on it, with the nozzles facing the inner wall of the mixing drum.

[0068] The above technical solution also includes a control box, which is installed on the base. The control box contains a controller, which is electrically connected to the drive device, the steel fiber dispersing device, the concrete conveying device, the heating device of the finishing roller, the hydraulic pump station, and the high-pressure water pump.

[0069] Furthermore, the above technical solution 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 finishing roller to detect the temperature of the concrete inside the mixing drum and the surface temperature of the finishing roller; the pressure sensor is installed on the hydraulic cylinder to detect the working pressure of the hydraulic cylinder; the position sensor is installed on the finishing plate to detect the position of the finishing plate; all sensors are electrically connected to the controller.

[0070] Furthermore, in the above technical solution, the controller is equipped 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:

[0071] S10. Receive data from the temperature sensor, pressure sensor, and position sensor, and initialize the system according to preset parameters;

[0072] S20. Start the steel fiber dispersion device to evenly disperse the steel fibers into the mixing drum;

[0073] S30. Control the start of the concrete conveying device to convey the predetermined amount of concrete raw materials into the mixing drum;

[0074] S40. The control drive device is started, which drives the mixing drum and mixing shaft to rotate, and fully mixes the concrete and steel fibers.

[0075] S50. Monitor the concrete temperature inside the mixing drum. When the temperature reaches the preset value, control the heating device of the finishing roller to start and heat the finishing roller to the preset temperature.

[0076] S60. Control the tilt of the mixing drum and slowly pour the well-mixed high-viscosity concrete onto the finishing roller.

[0077] S70. Control the hydraulic pump station to start, drive the hydraulic cylinder to lower the finishing plate, and compact the concrete on the finishing roller.

[0078] S80. Based on 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. After the dough collection process is completed, the cleaning device is started to clean the mixing drum, mixing shaft and dough collection roller, completing one work cycle.

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

[0081] 1. Base: The base is made of a rectangular steel plate, measuring 2000mm × 1500mm × 20mm. This thickness provides sufficient load-bearing capacity while ensuring the stability of the entire system. The base material is high-quality carbon steel, treated with pickling, sandblasting, and hot-dip galvanizing, exhibiting excellent corrosion resistance and wear resistance. Fixing holes are provided at the four corners of the base for securely installing the entire system on the ground.

[0082] 2. Support Frame: The support frame consists of three parts: a left column, a right column, and a top beam. The left and right columns are made of φ150mm×10mm thick-walled seamless steel pipes, coated with anti-corrosion paint. The columns are welded to the base using flanges. The top beam is made of φ120mm×8mm seamless steel pipe, welded at both ends to the tops of the left and right columns, forming a rigid spatial frame structure. This support frame design is not only reliable and durable but also effectively transmits various external loads, ensuring the overall stability of the entire system.

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

[0084] The inner wall of the cylinder is welded axially with 16 stirring blades, each 8mm thick and 500mm long, arranged in a spiral pattern. This design generates a good airflow for mixing, ensuring thorough mixing of concrete and steel fibers. Simultaneously, an 80mm diameter stirring shaft is installed inside the cylinder, with both ends mounted on the left and right end covers via bearing seats. Sixteen 12mm thick, 800mm long stirring arms are welded axially onto the stirring shaft, arranged radially. The right end of the stirring shaft is connected to the output shaft of the drive unit via a coupling, enabling the driving of the stirring shaft.

[0085] 4. Drive Unit: The drive unit uses a 7.5kW three-phase asynchronous motor with a rated speed of 1450r / min. The motor is mounted on the right column, and its output shaft is connected to the coupling at the right end of the mixing drum, used to drive the rotation of the mixing drum and the mixing shaft. The motor speed can be steplessly adjusted via a matching frequency converter to adapt to the mixing requirements under different working conditions.

[0086] 5. Steel Fiber Dispersion Device: The steel fiber dispersion device is located above the top beam and mainly consists of four parts: storage hopper, spiral conveyor pipe, vibrating screen, and dispersion disc.

[0087] The storage hopper adopts a conical structure with a diameter of φ800mm × 1000mm, with the upper opening being the feed inlet and the lower opening being the discharge outlet, and is made of 304 stainless steel. This size can hold a sufficient amount of steel fiber raw materials. Four φ20mm lifting lugs are welded to the outer wall of the hopper for hoisting and fixing to the top beam.

[0088] The screw conveyor pipe is made of seamless steel pipe with a diameter of φ150mm×2000mm, and has internal screw conveyor blades with a diameter of φ120mm×1950mm. The blade pitch is 100mm, and the material is high-quality carbon steel. The feed end of the screw conveyor pipe is connected to the discharge port of the storage hopper, and the discharge end is installed above the vibrating screen. This device can slowly convey steel fiber raw materials in the storage hopper to the vibrating screen.

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

[0090] The dispersing disc has a diameter of 800mm and an upper surface with a 30° conical inclination. It is made of 304 stainless steel. Twenty-four φ20mm discharge holes are evenly distributed along the edge of the disc. The dispersing disc is installed below the vibrating screen and is used to spray the filtered and dispersed steel fibers into the mixing drum.

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

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

[0093] The screw pump uses a 10m 3 The pump has a conveying capacity of 4kW / h. The pump body is made of gray cast iron, and the spiral blades are made of high-quality carbon steel. The pump's inlet connects to the hopper's outlet, and the outlet is connected via a DN100 conveying pipe. This pump can transport concrete raw materials from the hopper to the mixing drum.

[0094] The delivery pipe is a thick-walled PVC pipe with a diameter of 100mm and a diameter of 3000mm, and an 80mm nozzle is installed at the end of the pipe. The nozzle outlet faces the center of the mixing drum, which is used to accurately spray the concrete raw materials into the mixing area.

[0095] 7. Dough Roller: The dough roller has 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. The roller body is mounted on left and right columns at both ends via bearing seats, allowing it to rotate freely.

[0096] The roller surface has 24 spiral grooves evenly distributed circumferentially, 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, improving surface smoothness.

[0097] The roller body is equipped with a heating device, including eight φ10mm stainless steel heating wires and two PT100 temperature sensors. The heating wires are wound around the inner wall of the roller body, capable of heating the roller body to approximately 150°C. The temperature sensors are installed on the inner surface of the roller body to monitor the roller surface temperature in real time, providing feedback for heating control. Simultaneously, one end of the roller body has a φ20mm water inlet and outlet, which are connected to an external water source and drainage pipe via a rotary joint, allowing for cooling control of the heating device.

[0098] 8. Finishing Plate: The finishing plate is a rectangular steel plate structure measuring 800mm × 1500mm × 50mm, made of 45# carbon steel. The bottom surface of the plate has 24 evenly distributed triangular embossed patterns, matching the spiral grooves on the surface of the finishing roller.

[0099] The pressure plate is mounted above the top beam by three φ80mm hydraulic cylinders. The cylinder bodies are fixed to the top beam, and the piston rod ends are hinged to the back of the pressure plate. The three hydraulic cylinders are arranged in a 120° triangular distribution, which can reliably support and drive the lifting and lowering movement of the pressure plate.

[0100] The hydraulic cylinder can operate at a pressure of up to 15 MPa and is connected to a hydraulic pump station mounted on a base via hydraulic lines. The hydraulic pump station includes a 2.2 kW motor-driven piston pump, which provides the necessary pressurized oil to the hydraulic cylinder. The lifting position of the pressure plate is monitored by a position sensor mounted 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 capacity rectangular steel tank, measuring 1000mm × 800mm × 1250mm, made of carbon steel, and coated with epoxy resin. The water tank is fixedly installed on the upper part of the base and connected to the inlet of the high-pressure water pump via a pipe.

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

[0104] The water spray pipe is 6000mm long and 50mm in diameter, made of stainless steel. Forty-eight nozzles, each 10mm in diameter, are evenly distributed along the length of the mixing drum, with the nozzles angled towards the inner wall of the drum. This 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 roller, ensuring the equipment is clean and hygienic.

[0105] In addition, the system includes a control box mounted on the base, containing a controller. The controller is electrically connected to the drive unit, steel fiber dispersion unit, concrete conveying unit, finishing roller heating unit, hydraulic pump station, and high-pressure water pump. It is also connected to temperature sensors, pressure sensors, and position sensors to monitor the operating status of each component of the system.

[0106] The specific workflow of the system is described below:

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

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

[0109] S10-1: Receives signals from the temperature sensor to obtain the initial temperature T0 of the concrete inside the mixing drum. The temperature sensor is installed on the inner wall of the mixing drum and can monitor the temperature changes of the concrete in real time.

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

[0111] S10-3: Receives signals from the position sensor to obtain the initial position of the face-forming plate. The position sensor is installed on the face-forming plate and can provide feedback on the lifting and lowering position information of the plate.

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

[0113] This step allows the system to grasp the initial working conditions of the concrete, hydraulic system, and finishing mechanism, providing necessary reference for subsequent process control.

[0114] Step S20: Start the steel fiber dispersion 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 the hopper's discharge. The discharge port at the bottom of the storage hopper opens, slowly conveying the stored steel fiber raw material to the feed end of the spiral conveyor pipe.

[0117] S20-2: The controller simultaneously sends a start signal to the drive motor of the spiral conveyor pipe, driving the spiral blades to rotate and transporting the steel fibers along the pipe 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 vibrate at high frequency. Under the action of vibration, the steel fibers are fully dispersed and broken, falling from the screen onto the dispersing disc.

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

[0120] Through this step, the system can effectively disperse pre-stored steel fibers into the concrete inside the mixing drum through a controlled conveying, dispersing, 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 the 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 delivery pipe, and the concrete raw materials are sprayed into the central area inside the mixing drum under high pressure.

[0126] This step allows the system to precisely deliver the required concrete materials into the mixing drum, preparing for subsequent mixing and finishing.

[0127] Step S40: Start the 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 drive unit, causing the stirring drum and stirring shaft to rotate at a certain speed ω. The value of ω can be obtained in real time by the speed sensor of the drive unit.

[0130] S40-2: Under the linkage of the mixing drum and the mixing shaft, the concrete and steel fibers inside the drum are fully mixed, achieving complete mixing of the materials.

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

[0132] S40-4: Based on the stirring efficiency formula By combining the real-time acquired ω, R, ρ, and μ data, the current stirring efficiency E is calculated. m Where k1, k2, and k3 are undetermined 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 rotation speed ω of the stirring drum until E... m The requirements are met.

[0134] This step ensures that the concrete and steel fibers are thoroughly and evenly mixed, creating favorable conditions for subsequent molding and finishing.

[0135] Step S50: Heating the dough roller

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

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

[0138]

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

[0140] S50-2: Once the concrete temperature T(t) is detected to reach 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 heat to the surface of the dough roller through radiation and conduction, so that it quickly heats up to the predetermined temperature.

[0142] S50-4: At the same time, the controller will also start the cooling water circulation system inside the roll, and deliver cooling water into the roll body through the inlet and outlet to precisely control the heating process and ensure that the surface temperature of the roll is stable.

[0143] Through this step, the system can actively adjust the temperature of the finishing roller based on the real-time monitoring results of the concrete temperature, ensuring that the temperature of the concrete and the finishing roller are matched during the finishing process, thereby improving the molding quality.

[0144] Step S60: Tilting the stirring 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 tilt angle of the drum reaches about 10°.

[0147] S60-2: Under the action of gravity, the highly viscous concrete that is thoroughly mixed 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 it for the subsequent finishing process.

[0149] This step allows the system to smoothly deliver the mixed concrete to the top of the finishing roller, preventing flow interruptions or instability during the finishing process and ensuring finishing quality.

[0150] Step S70: Start compaction and finishing

[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 descend slowly, which in turn moves the finishing plate towards the concrete surface.

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

[0154]

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

[0156] S70-3: Under controlled pressure, the pressure plate repeatedly compacts the surface of the concrete flowing out of the mixing drum, gradually shaping it.

[0157] S70-4: The embossing on the bottom surface of the pressure plate and the spiral groove on the surface of the finishing roller work together to further improve the flatness of the concrete surface.

[0158] This step allows the system to precisely control the finishing pressure, ensuring a smooth and even concrete surface that meets usage requirements.

[0159] Step S80: Optimize the finishing quality

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

[0161] S80-1: The controller monitors the position of the pressing plate in real time and adjusts the driving force of the hydraulic cylinder according to the feedback signal from the position sensor, so that the pressing plate is always kept in the optimal working position.

[0162] S80-2: Simultaneously, the system will also perform 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 Let be the height of the i-th measurement point, h be the average height, β and γ be the weighting coefficients, and ε be the error term.

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

[0166] This step allows the system to monitor and precisely control the finishing process in real time, ensuring that the concrete surface ultimately achieves an ideal smooth and clean finish.

[0167] Step S90: Clean the equipment

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

[0169] S90-1: After the dough settling 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 roller through the water spray pipe.

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

[0172] S90-4: After cleaning, the system dries each component to prepare for the next work cycle.

[0173] This step enables the system to perform automated cleaning of the equipment regularly, ensuring that all components remain in good working order, extending the equipment's lifespan, and improving production efficiency.

[0174] In summary, the high-viscosity concrete finishing system with steel fibers, through a series of meticulously designed process steps from S10 to S90, achieves functions such as thorough mixing and dispersion of concrete, precise finishing, and regular cleaning and maintenance of the equipment. Each step employs corresponding measurement models, control algorithms, and automation technologies based on actual process requirements, ensuring 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 this invention has been successfully applied to the foundation engineering construction of a large-scale complex. Located in a coastal area, this complex consists of five 50-story office buildings and one 30-story hotel, with a total construction area of ​​1.5 million square meters. To ensure the safety and durability of the building foundations, the engineering design unit required the use of high-viscosity steel fiber reinforced concrete with excellent adhesion and crack resistance.

[0177] Based on 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 application verification at the project site. During the four-month practical application, the system demonstrated significant technical advantages, not only ensuring the excellent performance of the high-viscosity concrete products, but also greatly improving production efficiency, providing strong support for the project construction.

[0178] The specific application of this system in practice is summarized as follows:

[0179] 1. System Parameter Design: Based on the performance indicators of the high-viscosity concrete required for this project, the construction team designed the parameters for each functional module of the system, as follows:

[0180] Table 1 System Main Parameters and Design Specifications

[0181]

[0182]

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

[0184] 2. Process Parameter Optimization In addition to optimizing the design of hardware equipment parameters, the construction team also conducted in-depth research and debugging of the system's key process parameters, taking into account the unique characteristics of this high-viscosity concrete product. This mainly included:

[0185] (1) Steel fiber dispersion effect: Based on the mix proportion of the high-viscosity concrete used in this project, the construction team determined its density ρ to be 2450 kg / m³. 3 The dynamic viscosity μ is 12 Pa·s. The length L of the pre-added steel fiber is 30 mm, and the diameter d is 0.5 mm.

[0186] To ensure proper dispersion of steel fibers in concrete, the construction team determined the optimal process parameters by adjusting the vibration frequency of the vibrating screen and the rotation speed of the dispersion disc, as follows:

[0187] Vibrating screen frequency: 45Hz; dispersing disc rotation speed: 1200rpm

[0188] Under these process parameters, the construction team sampled and tested the dispersion of steel fibers in the concrete inside the mixing drum. The results showed that the fiber distribution was relatively uniform, with an average fiber content of 60 kg / m³. 3 The segregation rate is less than 5%, which meets the design requirements.

[0189] (2) Optimization of stirring efficiency: Based on the aforementioned stirring efficiency formula Based on the actual measured data of ρ, μ and ω, the construction team determined the optimal parameter combination of k1 = 0.18, k2 = 0.32 and k3 = 0.48 through experimental fitting.

[0190] With these parameter settings, the system can achieve a stirring efficiency E m Stable operation at ≥85% meets the requirements for concrete mixing quality. The construction team regularly samples and tests the mechanical properties of the concrete inside the mixing drum, and the results show that the compressive strength reaches 42MPa, which is consistent with the design specifications.

[0191] (3) Temperature control during dough preparation: Based on the aforementioned temperature prediction model The construction team determined the initial temperature T0 of the high-viscosity concrete to be 25℃, and the hydration heat release rate Q... h 220 J / s, mass m c It is 1800 kg, and its specific heat capacity is c. p The thermal time constant τ is 3600s, the ambient temperature fluctuation range A is 5℃, and the phase angle φ is π / 4.

[0192] According to the model's prediction, the concrete temperature will reach approximately 35℃ after 30 minutes of mixing. Therefore, the construction team set the target heating temperature of the finishing roller at 40℃ to ensure that the concrete surface temperature remains within the ideal range during the finishing process. In actual operation, the surface temperature of the finishing roller can be stably maintained between 39-41℃, which matches the concrete temperature well.

[0193] (4) Compaction Pressure Control: To accurately control the compaction pressure of the finishing plate, the construction team adopted a PID closed-loop control algorithm, based on the aforementioned pressure control model P(t)=P0+K p e(t)+ After debugging and optimization, K was determined. p =0.6, K i =0.12 and K d =0.03 control parameter.

[0194] Under these parameters, the system can adjust the initial pressure P0 to the set value Pset = 12MPa and track the pressure error e(t) in real time, quickly eliminating pressure fluctuations and ensuring that the pressure applied by the finishing platen to the concrete surface is stable and controllable. The construction team, through collecting pressure sensor data, found that the stability of the compaction pressure is better than ±0.3MPa, meeting the requirements for forming high-viscosity concrete.

[0195] (5) Surface smoothness assessment: Based on the aforementioned surface smoothness assessment model The construction team used a laser scanner to measure the surface of the finished concrete, with N=25 sampling points. After multiple trials and fitting, the optimal weighting parameters of β=0.4 and γ=0.6 were determined.

[0196] Measurement results show that the surface smoothness index F of the high-viscosity concrete product averages 2.1 mm, meeting the ±3 mm allowable deviation requirement of the engineering design. The construction team regularly inspects the finishing quality and finds that the incidence of defects such as surface ripples and pitting is less than 3%, far below the industry average.

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

[0198] 3. System Operation Status Since its commissioning, this high-viscosity concrete finishing system has provided production services for the foundation construction of this large building complex for nearly four months. During actual operation, all components of the system operated stably, product quality consistently met project requirements, and production efficiency was significantly improved. Specific details are as follows:

[0199] (1) Production efficiency: The system is designed to produce 10m³ per hour. 3 High-viscosity concrete products. Actual operation tracking shows the system produces an average of 9.6 m³ per hour. 3 The capacity utilization rate reached 96%, which is far higher than that of traditional mixing plants.

[0200] The construction team compared the production process using this system with the traditional method of transporting concrete by mixer trucks and manually finishing the surface. They found that the former reduced the overall production cost per unit by about 25%, significantly improving economic efficiency. The main reason is that the system achieves efficient dispersion of steel fibers, precise finishing of concrete, and automated cleaning of the equipment, greatly shortening the production cycle and reducing labor costs.

[0201] (2) Product Quality: During the four-month practical application period, the construction team regularly sampled and tested various performance indicators of the high-viscosity concrete product. The results showed that all indicators consistently met the design requirements. Specific data are as follows:

[0202] Table 2 Performance Indicators of High-Viscosity Concrete Products

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

[0204] (3) Equipment Operation Status Since its commissioning, the system has operated stably with all components, and the equipment failure rate is less than 3%, which is far superior to similar mechanical equipment. The construction team regularly cleans key components such as the inner wall of the mixing drum, the mixing shaft, and the finishing roller with high-pressure water, which effectively avoids the accumulation of concrete residue and extends the service life of the equipment.

[0205] Meanwhile, the system boasts a high degree of automation, with the controller capable of real-time monitoring and precise control of various process parameters such as temperature, pressure, and position, ensuring the stability and controllability of the entire production process. The construction team regularly inspected the system's sensors and actuators, finding them to be operating well with calibration deviations of less than 5%.

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

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

[0208] 1. High-Efficiency Steel Fiber Dispersion Mechanism: Addressing the challenge of dispersing steel fibers within high-viscosity concrete, this system employs a specialized steel fiber dispersion device to achieve efficient fiber dispersion. The combination of a storage hopper, a spiral conveyor pipe, and a vibrating screen allows for the slow, continuous, and initial dispersion of pre-added steel fiber raw materials, preventing entanglement and agglomeration during transport. Subsequently, a dispersion disc, through centrifugal force generated by high-speed rotation, evenly sprays the sieved steel fibers into the mixing drum, ensuring thorough dispersion of the fibers within the concrete matrix. This dispersion mechanism not only improves the utilization rate of steel fibers in concrete but also lays a solid foundation for subsequent mixing and molding processes.

[0209] 2. Precise Finishing Mechanism for High-Viscosity Concrete: Addressing the challenge of naturally shaping high-viscosity concrete, this system employs a finishing mechanism integrating heating and compaction, comprising a finishing roller and a finishing plate. The finishing roller is equipped with an internal heating wire, capable of heating the roller body to approximately 150°C. Upon contact with the high-temperature concrete surface, this generates excellent interfacial rheological effects, improving the concrete's fluidity and formability. Simultaneously, the finishing plate, driven by a precisely controlled hydraulic cylinder, applies pressure to the concrete surface on the roller, gradually shaping it during compaction. The embossed texture on the bottom surface of the plate matches the spiral grooves on the roller surface, further optimizing the smoothness of the concrete surface.

[0210] This heating-compacting finishing mechanism effectively overcomes the problem of high-viscosity concrete's difficulty in natural shaping, ensuring a smooth and flat final product surface that meets usage requirements. Simultaneously, real-time monitoring and feedback control of finishing parameters such as temperature and pressure further optimizes finishing quality and improves the controllability of the production process.

[0211] 3. Intelligent Control Logic of the System This invention employs a centralized controller to intelligently manage each functional module, achieving precise and coordinated control of processes such as steel fiber dispersion, concrete mixing, surface finishing, and equipment cleaning. The controller not only receives process parameter feedback signals from multiple sensors, including temperature, pressure, and position sensors, but also monitors and optimizes these parameters in real time based on a preset algorithm model, ensuring the stable operation of each process step.

[0212] For example, during the mixing process, the controller can adjust the mixing efficiency model. The stirring shaft speed ω is automatically adjusted to improve the stirring efficiency E. m To achieve the ideal values, the concrete and steel fibers are thoroughly mixed. During the finishing process, the controller also precisely controls the compaction pressure and the position of the compaction plate based on the hydraulic cylinder pressure PID model and the surface smoothness evaluation model, optimizing the forming 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 significantly enhances 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 this invention fully considers the key technical difficulties in the preparation and molding process of high-viscosity concrete. Through innovative designs such as a dedicated steel fiber dispersion device, a heating-compacting finishing mechanism, and intelligent process control, it effectively solves the pain points that existing technologies cannot address, and provides an advanced and reliable process technology solution for the production of high-performance concrete products in the future.

[0215] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A high-viscosity concrete finishing system with steel fibers, characterized in that, include: The system comprises a base, a support frame, a mixing drum, a drive unit, a steel fiber dispersing device, a concrete conveying device, a finishing roller, and a finishing plate. The base is a rectangular flat plate on which the support frame is fixedly mounted. The support frame includes a left column, a right column, and a top beam. The left and right columns are vertically mounted on the base, and the top beam horizontally connects the tops of the left and right columns. The mixing drum is cylindrical, with its two ends rotatably mounted on the left and right columns via bearing seats. The drive unit is mounted on the right column, and its output shaft is connected to the right end of the mixing drum. The steel fiber dispersing device is mounted on the top beam, with its outlet aligned with the upper opening of the mixing drum. The concrete conveying device is mounted on the left column, and its discharge pipe extends into the mixing drum. The finishing roller is a hollow cylindrical shape, with its two ends rotatably mounted on the left and right columns via bearings, and is located directly below the mixing drum. The finishing plate is a long strip. The concrete slab is mounted on the top beam via multiple hydraulic cylinders, with the finishing plate positioned directly above the finishing roller. It also includes a control box mounted on a base. The control box houses a controller electrically connected to the drive unit, steel fiber dispersion unit, concrete conveying unit, heating unit for the finishing roller, hydraulic pump station, and high-pressure water pump. Furthermore, it includes multiple sensors, including temperature, pressure, and position sensors. The temperature sensors are mounted on the mixing drum and the finishing roller to detect the temperature of the concrete inside the mixing drum and the surface temperature of the finishing roller. The pressure sensors are mounted on the hydraulic cylinders to detect their working pressure. The position sensors are mounted on the finishing plate to detect its position. All sensors are electrically connected to the controller. The controller contains a concrete finishing control module, which controls the steel fiber dispersion, concrete mixing, and finishing processes. The concrete finishing control module executes the following steps: S10. Receive data from the temperature sensor, pressure sensor, and position sensor, and initialize the system according to preset parameters; S20. Start the steel fiber dispersion device to evenly disperse the steel fibers into the mixing drum; S30. Control the start of the concrete conveying device to convey the predetermined amount of concrete raw materials into the mixing drum; S40. The control drive device is started, which drives the mixing drum and mixing shaft to rotate, and fully mixes the concrete and steel fibers. S50. Monitor the concrete temperature inside the mixing drum. When the temperature reaches the preset value, control the heating device of the finishing roller to start and heat the finishing roller to the preset temperature. S60. Control the tilt of the mixing drum and slowly pour the well-mixed high-viscosity concrete onto the finishing roller. S70. Control the hydraulic pump station to start, drive the hydraulic cylinder to lower the finishing plate, and compact the concrete on the finishing roller. S80. Based on 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. After the dough collection process is completed, the cleaning device is started to clean the mixing drum, mixing shaft and dough collection roller, completing one work cycle. Specifically, step S40 includes: S40-1: The controller sends a start signal to the motor of the drive device, driving the stirring drum and stirring shaft to rotate at a certain speed; S40-2: Under the linkage of the mixing drum and the mixing shaft, the concrete and steel fibers inside the drum are fully mixed, achieving complete mixing of the materials; 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 is determined by sampling and weighing, and the viscosity μ is measured by rotational viscometer. S40-4: According to the stirring efficiency formula By combining the real-time acquired ω, R, ρ, and μ data, the current stirring efficiency is calculated. ,in, Let ε be the coefficients to be determined, and let ε be the error term. Where is the radius of the mixing drum. For better mixing efficiency, ω represents the angular velocity of the stirring shaft; the value of ω is obtained in real time through the speed sensor of the drive unit. S40-5: If If the preset ideal value is not reached, the system automatically adjusts the rotation speed ω of the stirring drum until... The requirements are met.

2. The high-viscosity concrete finishing system with steel fibers according to claim 1, characterized in that, Multiple stirring blades are fixedly installed axially on the inner wall of the stirring cylinder, and the stirring blades are arranged in a spiral shape. A stirring shaft is also coaxially installed inside the stirring cylinder, and the two ends of the stirring shaft are rotatably installed on the left end cover and the right end cover of the stirring cylinder through bearing seats, respectively. Multiple stirring arms are fixedly installed axially on the stirring shaft, and the stirring arms are arranged radially. The right end of the stirring shaft is connected to the output shaft of the drive device through a coupling.

3. The high-viscosity concrete finishing system with steel fibers according to claim 2, characterized in that, The steel fiber dispersing device includes a storage hopper, a spiral conveying pipe, a vibrating screen, and a dispersing disc. The storage hopper is funnel-shaped and fixedly installed on a top beam. The inlet end of the spiral conveying pipe is connected to the outlet of the storage hopper, and spiral conveying blades are provided inside the spiral conveying pipe. The vibrating screen is installed below the outlet end of the spiral conveying pipe and has multiple screen holes. The dispersing disc is installed below the vibrating screen, and is disc-shaped with a conical upper surface. Multiple evenly distributed outlets are provided on the edge of the dispersing disc.

4. The high-viscosity concrete finishing system with steel fibers according to claim 3, characterized in that, The concrete conveying device includes a hopper, a screw pump, and a conveying pipe; the hopper is funnel-shaped and fixedly installed on the left column; the screw pump is installed below the hopper, and the inlet of the screw pump is connected to the outlet of the hopper; one end of the conveying pipe is connected to the outlet of the screw pump, and the other end of the conveying pipe extends into the mixing drum, with a nozzle 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 roller is provided with multiple evenly distributed grooves arranged in a spiral shape; the inside of the dough roller is provided with a heating device, which includes a heating wire and a temperature sensor; one end of the dough roller is provided with a water inlet and a water outlet, which are respectively connected to an external water source and a drain pipe through a rotary 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 plate has multiple evenly distributed embossed patterns, which match the grooves on the surface of the dough-collecting roller. The dough-collecting plate is connected to the top beam via at least three hydraulic cylinders. The piston rod end of the hydraulic cylinder is hinged to the dough-collecting plate, and the cylinder body of the hydraulic cylinder is fixedly connected to the top beam. The hydraulic cylinder is connected to a hydraulic pump station via hydraulic pipelines, and the hydraulic pump station is mounted on the 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 spray pipe; the water tank is fixedly installed on the base and is connected to the inlet of the high-pressure water pump through a pipe; the high-pressure water pump is installed on the base and its outlet is connected to the spray pipe through a pipe; the spray pipe is arranged along the length of the mixing drum and has multiple nozzles evenly distributed on it, with the nozzles facing the inner wall of the mixing drum.

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