Control system and control method for box girder web attached vibrator

Abstract

The invention discloses a control system and a control method for an attached vibrator of a box girder web, the control system comprises a remote handheld panel, an external Bluetooth signal receiving and transmitting module and a plug-in vibrator, and remote handheld panel software comprises attached vibrator control system software. The intelligent control cabinet is a hardware core of the whole web wall-attached vibration control system and mainly comprises a power protection switch, a power switch, an intelligent controller, a signal receiving and transmitting module and an air protection switch, and a web wall-attached vibrator control system program introduces concrete vibration plugging signal data of the walking plug-in vibrator and transmits the concrete vibration plugging signal data to the intelligent control cabinet. Determining real-time intelligent layering and zoning of a web concrete pouring range; and then a web attached vibrator control program can automatically and intelligently generate a single wall attached vibration task. Constructors can accurately control and reliably control attachment vibration conveniently, the purposes of uniform attachment vibration in web concrete pouring and compact and effective quality are achieved, and the device has the remarkable advantage of being convenient to use.

Description

Technical Field

[0001] The invention relates to the technical field of concrete construction, and in particular to a control system and a control method for a box beam web-attached vibrator. Background Art

[0002] The web and prestressed tendon anchorage areas of prefabricated box girders are narrow, with dense steel bars and several prestressed channels, which bring great inconvenience to the vibration of concrete. It is difficult to meet the requirements of the vibration compaction process by simply using an inserted vibrator from the inside, and quality defects such as voids, honeycombs and pockmarks are prone to occur. Therefore, the conventional process requires the installation of a high-frequency attached vibrator at a suitable position on the web outer mold to assist in vibration, in order to meet the requirements of the web vibration density and the apparent quality of concrete molding.

[0003] Prefabricated box girders generally have a large span, and a large number of attached vibrators are arranged at the web positions on both sides. The start and stop time and vibration range control of each wall-attached vibration have an important impact on the overall pouring quality of the web pouring area: if the wall-attached vibration time is controlled too short, it is difficult to make up for the vibration defects of the inserted vibrating rod; if the wall-attached vibration time is controlled too long, it is easy to cause over-vibration, resulting in appearance defects such as "sanding". Therefore, the start and stop and opening time and range of the attached vibrator in the vibration area must be strictly and accurately controlled. However, in fact, since the wall-attached vibration currently adopts manual observation of the material feeding vibration status, intercom communication instructions, and external specialists to control the wall-attached vibration, it is not easy to finely control it during implementation. If the automatic control system replaces manual operation, the vibration quality of concrete can be effectively guaranteed, saving manpower and reducing production costs.

[0004] The patent number is CN202222241616.0, and the patent name is "An attached vibrating device". It proposes to use the fence sensing device installed on both sides of the top plate to detect the pouring of concrete. The sensing unit sends a signal to the microprocessor, and the microprocessor sends a command to turn on the power of the vibrator to the relay. The relay controls the power switch to realize remote control of the start and stop of the vibrator. In the actual web concrete pouring process, the placing machine, construction personnel and other construction machinery on the top plate have a great influence on the infrared fence sensing device, which is very easy to cause misjudgment, resulting in invalid vibration, affecting construction efficiency and vibration quality. The patent number is CN202210606985.7, and the patent name is "An attached vibrating device". A mobile cast-in-place box girder bottom web concrete automatic vibrating device and its use method are proposed, but the device needs to be installed at the inner mold, which has certain requirements for the inner mold space and truss layout. At the same time, the device is only suitable for vibration operations at the bottom web of the box girder, and cannot meet the overall intelligent vibration requirements of the box girder web.

[0005] In the article entitled "Research on Quality Control Methods for Precast Beam Concrete Casting", with the journal number Sichuan Architecture, 2020, 40(04), Deng Na et al. proposed to write a program based on the original vibrator control cabinet to add control functions. The improved control cabinet can control the start and stop of 8 vibrators in a single unit. In the actual web casting process, each casting section will overlap and have different lengths. The control system will have some vibrators vibrating empty, and it cannot meet the refined vibration target of the box beam web. Summary of the invention

[0006] Purpose of the invention: The present invention proposes a control system and control method for a box girder web-attached vibrator, which can meet the requirements of fine and intelligent control, and is convenient for construction personnel to accurately control and reliably control the vibration of the attached wall, so as to achieve the purpose of uniform vibration of the attached wall during web concrete pouring and effective and dense quality.

[0007] Technical solution: The present invention proposes a control system for a box girder web attached vibrator, comprising an intelligent terminal, a Bluetooth signal transceiver module connected to the intelligent terminal, an intelligent control cabinet connected to the Bluetooth signal transceiver module, an attached vibrator and an inserted vibrator; the intelligent control cabinet comprises a power protection switch, a power switch connected to the power protection switch, an intelligent controller connected to the power switch, a signal transceiver module connected to the intelligent controller, and an air protection switch connected to the signal transceiver module; the Bluetooth signal transceiver module transmits information with the signal transceiver module, the air protection switch is connected to the attached vibrator, and the inserted vibrator is connected to the external Bluetooth signal transceiver module.

[0008] Preferably, the smart terminal is provided with a web-attached vibrator control system program linked with the smart control cabinet, the program is used to set the address of the attached vibrator, set the vibration time, set the number of synchronously started vibrators and feedback the working status of the vibrator, and finally automatically generate a single wall-attached vibration task.

[0009] Preferably, the web-attached vibrator control system program software linkage sends the vibration parameters and associated control instructions of the insert vibrator to the signal transceiver module in the intelligent control cabinet through the Bluetooth signal transceiver module. The signal transceiver module in the intelligent control cabinet can issue instructions to the intelligent controller in the intelligent control cabinet based on the received attached vibration requirement information.

[0010] Preferably, the external signal antenna of the signal transceiver module is fixed to the upper side of the intelligent control cabinet.

[0011] A control method for a box beam web-attached vibrator control system comprises the following steps:

[0012] S1: Preparation before construction, setting the basic parameters of the web-attached vibrator control system program;

[0013] S2: After completing S1, install the Bluetooth signal transceiver module;

[0014] S3: Comprehensively consider the spatial location of the box girder-attached vibrator on site and arrange the intelligent control cabinet reasonably;

[0015] S4: After completing S3, manually set the address of the intelligent controller;

[0016] S5: after completing S4, the vibration data of the inserted vibrator is imported into the control system program of the attached vibrator, and then the control system program performs precise control matching of the attached vibrator according to the control arrangement of the attached vibrator, outputs a single vibrator working address, and forms a single vibration control task;

[0017] S6: After completing S5, the completed vibration task data of the inserted vibrator in the web casting section are filtered out, and the starting point data of the next web casting section vibration task is sent to the inserted vibrator;

[0018] S7: The single vibration task instruction generated by the control system program of the web-attached vibrator is sent to the signal transceiver module in the intelligent control cabinet through the Bluetooth transceiver module; and then the signal transceiver module sends the single vibration task instruction to the intelligent controller.

[0019] S8: The intelligent controller receives the vibration task instruction from the signal transceiver module and determines whether the address at this time is consistent with the single vibration task address. If it is consistent, the intelligent controller outputs the instruction, otherwise the intelligent controller stops the instruction transmission;

[0020] S9: The air protection switch receives the vibration start instruction output by the intelligent controller, turns on the power switch to output power to the attached vibrator, and the attached vibrator starts the vibration work;

[0021] S10: After completing S9, a vibration countdown is performed. After the countdown is completed, the intelligent controller sends a vibration task shutdown instruction to the air protection switch;

[0022] S11: After receiving the task closing instruction of S10, the power switch is turned off to stop outputting power to the attached vibrator, the attached vibrator stops vibrating, and the single vibration task ends.

[0023] Preferably, the basic parameters of the web-attached vibrator control system program in S1 include an attached vibrator group number, an attached vibrator address and a vibration time.

[0024] Preferably, the attached vibrator address in the web-attached vibrator control system program in S4, the address of the intelligent controller and the attached vibrator installed on site correspond one to one.

[0025] Preferably, S5 includes the following steps: the inserted vibrator starts to perform inserted vibration on the web casting section, and after the inserted vibration is completed, the real-time concrete pouring range of the casting section and the inserted vibration quality result data are generated; the web attached vibrator control system program imports the vibration data of the inserted vibrator, the control system program filters the overlapping data of the last task, and generates the concrete depth and length range of the web casting section of this vibration task by analyzing the latest data, and the control system program generates a single vibration range; the control system program performs precise control matching of the attached vibrator according to the attached vibrator control layout, outputs a single attached vibrator working address, and forms a single vibration control task.

[0026] Preferably, when the attached vibrator in S6 starts to execute the current vibration task, the inserted vibrator starts the working mode at the same time according to the starting point of the next vibration.

[0027] Preferably, S10 specifically includes the following steps: after the intelligent controller outputs a vibration start instruction to the air protection switch, a countdown is performed when the vibration starts, and the LCD screen of the intelligent controller displays the remaining vibration time in real time; when the vibration countdown ends, the intelligent controller sends a vibration task shutdown instruction to the air protection switch.

[0028] Beneficial effect: The present invention sets the vibration program of the attached vibrator according to the web casting process of the box beam, and can achieve automation of the web casting process of the box beam. Compared with the existing technology in which after each web casting section is completed with inserted vibration in the web casting process of ordinary cast-in-place beams, it is necessary to communicate with the start and stop control personnel of the attached vibrator through an intercom, and then the control personnel completes the start and stop of the attached vibrator, the scheme of the present invention is preset with program instructions, and the remote intelligent start and stop of the wall vibrator is realized through the intelligent controller, which reduces at least half of the wall vibrator operators, saves labor costs, and improves the efficiency of the box beam concrete wall vibration operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 A schematic flow chart of a control method for a box beam web-attached vibrator control system according to the present invention;

[0030] Figure 2 A schematic diagram of a process for determining the pouring section in real time and automatically identifying and allocating an attached vibrator according to the plug-in and pull-out vibration signals in the present invention;

[0031] Figure 3 A schematic diagram of a control system for a box girder web-attached vibrator in the present invention;

[0032] Figure 4 Schematic diagram of the structure of the intelligent control cabinet in the invention.

[0033] Among them, 1. Smart terminal; 2. Bluetooth signal transceiver module; 3. Smart control cabinet; 4. Attached vibrator; 5. Power protection switch; 6. Power switch; 7. Smart controller; 8. Signal transceiver module; 9. Air protection switch; 10. Plug-in vibrator. DETAILED DESCRIPTION

[0034] See also Figure 3 and Figure 4 The present invention proposes a control system for a web-attached vibrator of a box girder, comprising an intelligent terminal 1, an intelligent control cabinet 3, a Bluetooth signal transceiver module 2, the Bluetooth signal transceiver module 2 is provided with a 12V battery block for power supply, and the intelligent terminal 1 is provided with a web-attached vibrator control system software. The intelligent control cabinet 3 is the core of the entire web-attached control system, mainly including a power protection switch 5, a 380V to DC 12V power switch 6, an intelligent controller 7, a signal transceiver module 8 and a 380V air protection switch 9.

[0035] The Bluetooth signal transceiver module 2 is connected to the intelligent terminal 1, and is also connected to the intelligent control cabinet 3 and the plug-in vibrator 10; the power protection switch 5 is connected to the power switch 6, the power switch 6 is connected to the intelligent controller 7, the intelligent controller 7 is connected to the signal transceiver module 8, and the signal transceiver module 8 is connected to the air protection switch 9; the Bluetooth signal transceiver module 2 transmits information to the signal transceiver module 8, and the air protection switch 9 is connected to the attached vibrator 4.

[0036] See also Figure 1-2 ,A control method for a box beam web attached vibrator control system,, comprising the following steps:

[0037] S1: Preparation before construction, setting the basic parameters of the web-attached vibrator control system program;

[0038] S2: After completing S1, install Bluetooth signal transceiver module 2;

[0039] S3: Comprehensively consider the spatial position of the box girder attached vibrator 4 on site and arrange the intelligent control cabinet 3 reasonably;

[0040] S4: After completing S3, manually set the address of the intelligent controller 7;

[0041] S5: after completing S4, the vibration data of the inserted vibrator 10 is imported into the control system program of the attached vibrator, and then the control system program controls the layout of the attached vibrator 4, performs precise control matching of the attached vibrator 4, outputs a single vibrator working address, and forms a single vibration control task;

[0042] S6: After completing S5, the completed vibration task data of the inserted vibrator 10 in the web casting section are filtered out, and the starting point data of the next web casting section vibration task is sent to the inserted vibrator 10;

[0043] S7: The single vibration task instruction generated by the web-attached vibrator control system program is sent to the signal transceiver module 8 in the intelligent control cabinet through the Bluetooth transceiver module 2; and then the signal transceiver module 8 sends the single vibration task instruction to the intelligent controller 7.

[0044] S8: The intelligent controller 7 receives the vibration task instruction from the signal transceiver module 8, and determines whether the address at this time is consistent with the single vibration task address. If it is consistent, the intelligent controller 7 outputs the instruction, otherwise the intelligent controller 7 stops the instruction transmission;

[0045] S9: the air protection switch 9 receives the vibration start instruction output by the intelligent controller, turns on the power switch 6 to output power to the attached vibrator, and the attached vibrator 4 starts the vibration operation;

[0046] S10: After completing S9, a vibration countdown is performed. After the countdown is completed, the intelligent controller 7 sends a vibration task closing instruction to the air protection switch 9;

[0047] S11: After receiving the task closing instruction of S10, the power switch 6 is turned off to stop outputting power to the attached vibrator 4, the attached vibrator 4 stops vibrating, and the single vibration task is completed.

[0048] In step S1, the preparation before construction is to complete the setting of the software parameters of the control system of the attached vibrator of the web of the box girder according to the vibration requirements of the prefabricated web of the box girder, mainly including the group number of the attached vibrator, the address of the attached vibrator and the vibration time. According to the standard wall-attached vibration parameter requirements required for the actual pouring division of the vibration unit, the refined auxiliary vibration of the precise vibration section is implemented to effectively avoid under-vibration and over-vibration.

[0049] In step S2, the Bluetooth signal transceiver module 2 is installed, and the signal antenna is installed in a relatively open and safe place at the construction site to ensure that the signal transmission and reception process is not interfered with, and at the same time ensure that the 12V battery pack of the Bluetooth signal transceiver module 2 is fully charged.

[0050] In step S3, the intelligent control cabinet 3 is reasonably arranged in combination with the installation position of the on-site box girder attached vibrator 4. After the intelligent control cabinet 3 is installed, the address of the attached vibrator is set for the intelligent controller 7. It should be noted that the program software of the box girder web attached vibrator control system sets the address of the attached vibrator, the on-site attached vibrator 4 and the intelligent controller 3 in a one-to-one correspondence.

[0051] This design can give an address alarm in time when the attached vibrator 4 and the intelligent controller 3 fail, making it convenient for on-site construction personnel to deal with the failure or replace equipment in time, ensuring that the box girder web concrete pouring task is not blocked.

[0052] In step S5, during the construction of the web of the box girder, after the concrete of the web casting section is put into the mold, the inserted vibrator 10 set up above the box girder starts the inserted vibration. After the inserted vibration is completed, the real-time concrete casting range and inserted vibration quality result data of the casting section are automatically generated. The control system program of the box girder web attached vibrator imports the vibration data of the inserted vibrator 10, and intelligently layers and zones according to the casting range of the web concrete of the box girder in real time. The control system program of the box girder web attached vibrator generates vibration tasks, divides the wall-attached vibration unit, and realizes accurate and complete vibration coverage of the web concrete casting section completed by the inserted vibrator 10. At the same time, according to the vibration quality of the web concrete by the inserted vibration, a unified vibration parameter is set, and the start and stop and vibration time of the attached vibrator of the web casting section are intelligently controlled. This design adapts to the complex casting conditions on site, realizes accurate vibration of the web casting section, avoids invalid vibration of the casting area, and reduces vibration noise at the same time, achieving the purpose of green, saving and noise reduction.

[0053] After the web-attached vibrator control system program generates a single vibration task in step S6, the vibration task data completed by the inserted vibrator 10 in the web casting section is screened out, and the starting point data of the next web casting section vibration task is sent to the inserted vibrator 10. When the attached vibrator 4 starts to execute this vibration task, the inserted vibrator 10 simultaneously starts the working mode according to the set starting point of the next vibration. This design, on the one hand, avoids the inserted vibrator 10 from repeatedly vibrating the single vibration range of the attached vibrator 4, and on the other hand, the inserted vibrator 10 and the attached vibrator 4 realize orderly work alternation, avoid excessive work crossover time, and improve construction efficiency.

[0054] In step S7, the box girder web attached vibrator control system program software sends the web concrete vibration parameters to the signal transceiver module 8 in the intelligent control cabinet 3 through the Bluetooth signal transceiver module 2. The signal transceiver module 8 in the intelligent control cabinet 3 can send the received instructions issued by the remote handheld flat box girder web attached vibrator control program to the intelligent controller 7 in the intelligent control cabinet 3.

[0055] Compared with the manual intercom communication of the traditional web-attached vibrator, this design transmits vibration instructions accurately and quickly, which can achieve accurate and timely vibration of concrete in the web casting section, ensure the vibration quality of the web concrete, and also reduce the number of construction personnel and save labor costs.

[0056] In steps S9-S11, the LCD screen of the intelligent controller 7 displays the address and working status of the attached vibrator at the outer template of the web in real time, and displays the countdown of the vibration time when the vibration is turned on. During the concrete pouring and vibration construction, the intelligent controller (7) inputs the signal current emitted by the signal transceiver module 8 in the intelligent control cabinet 3, and the intelligent controller 7 analyzes and judges the web pouring vibration parameter signal current output to the 380v air protection switch 9. The 380v air protection switch 9 receives the signal current output by the intelligent controller 7, stimulates the 380v air protection switch 9 to turn on, sets the vibration time to end, stimulates the 380v air protection switch 9 to turn off the power input, and ends the vibration. During the concrete vibration construction process of the web pouring section, the start and stop of the attached vibrator 4 is automated, which can replace the cumbersome manual start and stop, and reduce the number of construction personnel at the same time.

[0057] In this example, the box girder is a standard 32m double-track railway box girder, using C50 concrete with a slump of 16-18cm. It was poured continuously for 8 hours and controlled by this method. The wall vibration on both sides was implemented in layers and sections, and the wall vibration of the web structure was finely controlled for more than 160 times. After the box girder web was demolded, there was no honeycombed surface and all structural strength tests were excellent.

Claims

1. A control system for a box beam web-attached vibrator, characterized in that: The invention comprises an intelligent terminal (1), a Bluetooth signal transceiver module (2) connected to the intelligent terminal (1), an intelligent control cabinet (3) connected to the Bluetooth signal transceiver module (2), an attached vibrator (4) and an inserted vibrator (10); the intelligent control cabinet (3) comprises a power protection switch (5), a power switch (6) connected to the power protection switch (5), an intelligent controller (7) connected to the power switch (6), a signal transceiver module (8) connected to the intelligent controller (7), and an air protection switch (9) connected to the signal transceiver module (8); the Bluetooth signal transceiver module (2) transmits information to the signal transceiver module (8), the air protection switch (9) is connected to the attached vibrator (4), and the inserted vibrator (10) is connected to the external Bluetooth signal transceiver module (2).

2. The control system for a box beam web-attached vibrator according to claim 1, characterized in that: The intelligent terminal (1) is provided with a web-attached vibrator control system program linked to the intelligent control cabinet, the program is used to set the address of the attached vibrator, set the vibration time, set the number of synchronously turned-on vibrators and feedback the working status of the vibrators, and finally automatically generate a single wall-attached vibration task.

3. The control system for a box beam web-attached vibrator according to claim 2, characterized in that: The web-attached vibrator control system program software transmits the vibration parameters and associated control instructions of the inserted vibrator (10) to the signal transceiver module (8) in the intelligent control cabinet (3) via the Bluetooth signal transceiver module (2); the signal transceiver module (8) in the intelligent control cabinet (3) can issue instructions to the intelligent controller (7) in the intelligent control cabinet based on the received attached vibration requirement information.

4. The control system for a box beam web-attached vibrator according to claim 1, characterized in that: The external signal antenna of the signal transceiver module (8) is fixed to the upper side of the intelligent control cabinet (3).

5. A control method for a box beam web-attached vibrator control system according to any one of claims 1 to 4, characterized in that: The following steps are involved: S1: Preparation before construction, setting the basic parameters of the web-attached vibrator control system program; S2: After completing S1, install the Bluetooth signal transceiver module (2); S3: Comprehensively consider the spatial position of the on-site box girder attached vibrator (4) and reasonably arrange the intelligent control cabinet (3); S4: After completing S3, manually set the address of the intelligent controller (7); S5: after completing S4, the vibration data of the inserted vibrator (10) is imported into the control system program of the attached vibrator, and then the control system program performs precise control matching of the attached vibrator according to the control arrangement of the attached vibrator, outputs a single vibrator working address, and forms a single vibration control task; S6: after completing S5, the completed vibration task data of the web casting section insert vibrator (10) are screened out, and the starting point data of the next web casting section vibration task is sent to the insert vibrator (10); S7: The single vibration task instruction generated by the control system program of the web-attached vibrator is sent to the signal transceiver module (8) in the intelligent control cabinet (3) through the Bluetooth transceiver module (2); and the signal transceiver module (8) then sends the single vibration task instruction to the intelligent controller (7). S8: the intelligent controller (7) receives the vibration task instruction from the signal transceiver module, and determines whether the address at this time is consistent with the single vibration task address. If it is consistent, the intelligent controller (7) outputs the instruction, otherwise the intelligent controller (7) stops the instruction transmission; S9: the air protection switch (9) receives the vibration start instruction output by the intelligent controller, turns on the power switch (6) to output power to the attached vibrator (4), and the attached vibrator (4) starts the vibration operation; S10: after completing S9, a vibration countdown is performed, and after the countdown is completed, the intelligent controller (7) sends a vibration task closing instruction to the air protection switch (9); S11: After receiving the task closing instruction of S10, the power switch (6) is turned off to stop outputting power to the attached vibrator (4), the attached vibrator (4) stops vibrating, and the single vibration task is completed.

6. The control method for a box beam web-attached vibrator control system according to claim 5, characterized in that: The basic parameters of the web-attached vibrator control system program in S1 include the attached vibrator group number, the attached vibrator address and the vibration time.

7. The control method for a box beam web-attached vibrator control system according to claim 5, characterized in that: The attached vibrator address in the web-attached vibrator control system program in S4, the address of the intelligent controller (7) and the attached vibrator (4) installed on site correspond one to one.

8. The control method for a box beam web-attached vibrator control system according to claim 5, characterized in that: The S5 comprises the following steps: the inserted vibrator (10) starts to perform inserted vibration on the web casting section, and after the inserted vibration is completed, generates the real-time concrete casting range of the casting section and the inserted vibration quality result data; the web attached vibrator control system program imports the vibration data of the inserted vibrator (10), the control system program filters the overlapping data of the previous task, generates the web casting section concrete depth and length range of this vibration task by analyzing the latest data, and the control system program generates a single vibration range; the control system program performs precise control matching of the attached vibrator (4) according to the control arrangement of the attached vibrator (4), outputs the single attached vibrator (4) working address, and forms a single vibration control task.

9. The control method for a box beam web-attached vibrator control system according to claim 5, characterized in that: When the attached vibrator (4) in S6 starts to perform the current vibration task, the inserted vibrator (10) starts the working mode at the same time according to the next vibration starting point.

10. The control method for a box beam web-attached vibrator control system according to claim 5, characterized in that: The step S10 specifically comprises the following steps: after the intelligent controller (7) outputs a vibration start instruction to the air protection switch (9), a countdown is performed when vibration starts, and the liquid crystal display screen of the intelligent controller (7) displays the remaining vibration time in real time; when the vibration countdown ends, the intelligent controller (7) sends a vibration stop task instruction to the air protection switch (9).

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