Concrete curing integrated system

Abstract

The invention provides a concrete curing integrated system, and belongs to the technical field of concrete curing, the concrete curing integrated system comprises a curing box body, a top cover plate, a support base and a water adding device; a curing box body is arranged on the supporting base, the curing box body is of a cubic structure, an opening is formed in the top of the curing box body, and a top cover plate is installed at the opening; a water inlet is formed in the top cover plate, and a water adding device is mounted at the water inlet; the water adding device comprises a water tank body, a water tank baffle and a spraying system; the water tank body is fixedly mounted at the upper end of the top cover plate at the water inlet; the bottom of the water tank body is connected with a spraying system, and the spraying system extends into the curing box body; a heating disc is arranged at the bottom end in the curing box body and is connected with an external power supply through a wire; and a temperature sensor and a humidity sensor are arranged on one side wall of the curing box body. The problem that manual intervention is frequent in the concrete field curing process can be solved.

Description

Technical Field

[0001] The present invention belongs to the technical field of concrete curing, and in particular, relates to an integrated concrete curing system. Background Art

[0002] As one of the main materials of modern construction, the performance of concrete directly affects the quality and service life of buildings. On-site construction and maintenance of concrete is a key link to ensure that concrete obtains good performance. Reasonable maintenance can enhance the strength, durability and impermeability of concrete. Traditional concrete maintenance methods mainly include watering maintenance, covering maintenance and steam maintenance. Watering maintenance keeps the concrete surface moist by regular watering, but there are problems such as troublesome manual operation, high water resource consumption and unstable maintenance effect. Especially in large-scale projects, manual watering is difficult to ensure the continuity and uniformity of maintenance. Covering maintenance uses covering materials such as plastic film or sacks to isolate the external environment and keep the interior of the concrete moist, but it requires regular manual inspection and replacement, and is not conducive to the temperature control of the concrete. Steam maintenance promotes hydration reaction through high-temperature steam, which can accelerate strength development, but the equipment investment is large, the energy consumption is high, and it is easy to cause cracks on the concrete surface.

[0003] Therefore, the existing concrete on-site curing technology has the following main problems:

[0004] 1) Imprecise control of curing environment parameters makes it difficult to ensure that concrete is always in the best curing environment, resulting in uneven strength development and affecting concrete quality;

[0005] 2) Frequent manual intervention in the maintenance process, low automation level and low maintenance efficiency;

[0006] 3) The system structure is simple, but it is difficult to ensure the uniformity and effectiveness of maintenance in order to cope with the complex terrain and huge amount of concrete pouring in large-scale projects;

[0007] 4) The lack of dynamic monitoring and feedback control of parameters such as temperature and humidity makes it difficult to achieve intelligent maintenance. Summary of the invention

[0008] In view of this, the present invention provides an integrated concrete curing system, which can solve the problem of frequent manual intervention in the on-site concrete curing process.

[0009] The present invention is achieved in that:

[0010] The present invention provides an integrated concrete curing system, which comprises: a curing box, a top cover plate, a support base and a water adding device; the support base is provided with a curing box, the curing box is a cubic structure, the top of the curing box is provided with an opening, and the opening is installed with a top cover plate; the top cover plate is provided with a water inlet, and the water adding device is installed at the water inlet; the water adding device comprises a water tank body, a water tank baffle and a spray system, the water tank body is fixedly installed at the upper end of the top cover plate at the water inlet; the bottom of the water tank body is connected with the spray system, and the spray system extends to the inside of the curing box; a heating plate is provided at the bottom end of the inside of the curing box, and the heating plate is connected to an external power supply through a wire; a temperature sensor and a humidity sensor are provided on one side wall of the curing box, and the temperature sensor and the humidity sensor both pass through the side wall of the curing box and extend to the inside of the curing box; a drain outlet is provided at the bottom of the other side wall of the curing box, and a drain valve is installed at the drain outlet.

[0011] The technical effects of the integrated concrete curing system provided by the present invention are as follows: The integrated concrete curing system of the present invention has the following significant technical advantages:

[0012] 1. Precise control of temperature and humidity. The system has built-in temperature sensors and humidity sensors, which can monitor the temperature and humidity of the curing environment in real time, and accurately adjust the temperature and humidity parameters through the heating plate and spray system to ensure constant temperature and humidity in the curing environment, providing guarantee for the best curing conditions for concrete.

[0013] 2. Automated maintenance process. The system integrates functional modules such as heating, water addition, drainage, and data recording, which can realize fully automated maintenance process control, greatly reduce manual operations, and improve work efficiency. The control chip automatically adjusts the heating power and water supply according to the pre-set maintenance time curve, monitors temperature and humidity changes, and dynamically optimizes maintenance parameters to ensure stable and reliable maintenance quality.

[0014] 3. Intelligent maintenance management. The system uses advanced control algorithms, such as PID control, fuzzy control and neural network control, to achieve intelligent regulation of temperature and humidity. At the same time, the system collects and records temperature and humidity data, energy consumption data and operation status of the entire maintenance process to form a complete maintenance process data curve, providing a basis for subsequent maintenance quality analysis and optimization. Through big data analysis, the system can also adaptively adjust the maintenance strategy to improve the stability and reliability of concrete maintenance.

[0015] 4. Suitable for large-scale projects. The curing box adopts a cubic structure with large volume and strong bearing capacity. It can accommodate multiple concrete components for centralized curing at the same time, meeting the maintenance needs of large-scale engineering projects. The curing box adopts a heat preservation design, which can effectively reduce heat loss and improve curing efficiency. In addition, the box also has good sealing and corrosion resistance to ensure the stability of the curing environment.

[0016] In summary, the integrated concrete curing system of the present invention has made significant technological advances in terms of temperature and humidity control accuracy, curing automation level, and intelligent optimization of the curing process, which has greatly improved the efficiency and quality of concrete curing and provided an advanced and reliable curing solution for large-scale engineering projects.

[0017] On the basis of the above technical solution, the integrated concrete curing system of the present invention can also be improved as follows:

[0018] Among them, the support base includes a bottom plate, on which a front support frame and a rear support frame are symmetrically arranged front and back; the maintenance box is fixedly installed between the front support frame and the rear support frame; a control box is also fixed on the bottom plate, and a control chip is installed in the control box, and the control chip is electrically connected to the temperature sensor, humidity sensor, heating plate, water adding device and drain valve.

[0019] Furthermore, the spray system includes a main pipe and multiple branch pipes, the main pipe is connected to the top cover plate, and the multiple branch pipes are evenly distributed on the inner side of the top of the top cover plate; each branch pipe is provided with multiple atomizing nozzles for evenly spraying water mist; the spray system also includes a water pump, which is installed between the top cover plate and the main pipe to provide water pressure.

[0020] Furthermore, the top cover is arc-shaped and fits tightly with the opening of the maintenance box through a sealing ring to form a completely sealed cubic structure; an observation window is provided on the top cover, and the observation window is made of high-temperature resistant glass material to facilitate observation of the internal conditions of the maintenance box; a plurality of evenly distributed bolt holes are provided on the edge of the top cover, and the top cover is detachably connected to the maintenance box through bolts.

[0021] Furthermore, the heating plate adopts an electric heating wire heating method, and the electric heating wire is evenly distributed on the surface of the heating plate in a serpentine shape; the surface of the heating plate is covered with a corrosion-resistant coating to prevent the concrete from corroding the heating plate; an insulation layer is provided between the heating plate and the inner wall of the curing box, and the insulation layer is made of ceramic fiber material to improve the heating efficiency and prevent heat loss.

[0022] Furthermore, the temperature sensor and humidity sensor are both digital sensors with high precision and fast response characteristics; the measuring range of the temperature sensor is 0 to 100 degrees Celsius, with an accuracy of plus or minus 0.5 degrees Celsius; the measuring range of the humidity sensor is 0 to 100 percent relative humidity, with an accuracy of plus or minus 3 percent relative humidity; the temperature sensor and humidity sensor are both connected to the side wall of the maintenance box through a waterproof joint to ensure the accuracy of the measurement data and the sealing of the system.

[0023] Furthermore, the drain outlet is located near one side of the bottom of the maintenance box, and the inner diameter of the drain outlet is 30 mm; the drain valve is an electric ball valve structure, the valve body is made of stainless steel, and the valve stem is made of a polytetrafluoroethylene sealing ring to ensure long-term use without leakage; the drain valve is driven by a motor, and the motor is electrically connected to the control chip to achieve automatic control.

[0024] Furthermore, a plurality of evenly distributed reinforcing ribs are provided on the inner wall of the curing box, and the reinforcing ribs are distributed in a grid shape to enhance the structural strength of the curing box; the inner wall of the curing box is also coated with an anti-corrosion coating, and the anti-corrosion coating is made of epoxy resin material, which can effectively prevent concrete from corroding the curing box and extend the service life of the system; the outer wall of the curing box is provided with an insulation layer, and the insulation layer is made of polyurethane foam material with a thickness of 50 mm to reduce heat loss and improve curing efficiency.

[0025] Furthermore, a liquid level sensor is provided on the water tank body to monitor the amount of water in the water tank; a water inlet pipe is provided on the water tank body, a solenoid valve is installed on the water inlet pipe, and the solenoid valve is electrically connected to the control chip; when the liquid level sensor detects that the water amount is lower than a preset value, the control chip controls the solenoid valve to open and automatically replenish the water.

[0026] Furthermore, a maintenance control module is provided in the control chip, and the maintenance control module is used to control the temperature, humidity and water supply during the concrete curing process; the maintenance control module is used to perform the following steps:

[0027] S10, receiving temperature data and humidity data collected by the temperature sensor and the humidity sensor;

[0028] S20, judging whether the current maintenance environment meets the preset maintenance conditions according to the received temperature data and humidity data;

[0029] S30, if the current curing environment does not meet the preset curing conditions, adjusting the heating power of the heating plate or controlling the water adding device to add water;

[0030] S40, adjusting the heating power of the heating plate and the water supply of the water adding device according to the preset curing time curve;

[0031] S50, monitoring the temperature change rate and humidity change rate during the maintenance process, and if the change rate exceeds a preset threshold, adjusting the heating power or water supply accordingly;

[0032] S60, recording temperature data, humidity data, heating power data and water supply data during the maintenance process to form a maintenance process data curve;

[0033] S70, dynamically adjust subsequent maintenance parameters according to the maintenance process data curve to ensure the stability of the maintenance effect;

[0034] S80. During the maintenance process, regularly check the water accumulation in the maintenance box and start the drain valve to drain water when necessary;

[0035] S90: When the curing time reaches the preset value, the heating plate is controlled to stop heating, the water adding device stops supplying water, and the curing process ends.

[0036] Compared with the prior art, the beneficial effects of the integrated concrete curing system provided by the present invention are:

[0037] 1. Precise control of temperature and humidity. The system has built-in temperature sensors and humidity sensors, which can monitor the temperature and humidity of the curing environment in real time, and accurately adjust the temperature and humidity parameters through the heating plate and spray system to ensure constant temperature and humidity in the curing environment, providing guarantee for the best curing conditions for concrete.

[0038] 2. Automated maintenance process. The system integrates functional modules such as heating, water addition, drainage, and data recording, which can realize fully automated maintenance process control, greatly reduce manual operations, and improve work efficiency. The control chip automatically adjusts the heating power and water supply according to the pre-set maintenance time curve, monitors temperature and humidity changes, and dynamically optimizes maintenance parameters to ensure stable and reliable maintenance quality.

[0039] 3. Intelligent maintenance management. The system uses advanced control algorithms, such as PID control, fuzzy control and neural network control, to achieve intelligent regulation of temperature and humidity. At the same time, the system collects and records temperature and humidity data, energy consumption data and operation status of the entire maintenance process to form a complete maintenance process data curve, providing a basis for subsequent maintenance quality analysis and optimization. Through big data analysis, the system can also adaptively adjust the maintenance strategy to improve the stability and reliability of concrete maintenance.

[0040] 4. Suitable for large-scale projects. The curing box adopts a cubic structure with large volume and strong bearing capacity. It can accommodate multiple concrete components for centralized curing at the same time, meeting the maintenance needs of large-scale engineering projects. The curing box adopts a heat preservation design, which can effectively reduce heat loss and improve curing efficiency. In addition, the box also has good sealing and corrosion resistance to ensure the stability of the curing environment.

[0041] In summary, the integrated concrete curing system of the present invention has made significant technological advances in terms of temperature and humidity control accuracy, curing automation level, and intelligent optimization of the curing process, which has greatly improved the efficiency and quality of concrete curing and provided an advanced and reliable curing solution for large-scale engineering projects. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for use 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 ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0043] Figure 1 It is a front view of an integrated concrete curing system;

[0044] Figure 2 It is a schematic diagram of the internal structure of an integrated concrete curing system;

[0045] Figure 3 It is a schematic diagram of the execution steps of the maintenance control module;

[0046] In the accompanying drawings, the components represented by the reference numerals are listed as follows:

[0047] 10. Maintenance box; 11. Top cover; 12. Support base; 13. Water adding device; 131. Water tank body; 133. Spray system; 1331. Main pipeline; 1332. Branch pipeline; 1333. Atomizing nozzle; 1334. Water pump; 14. Heating plate; 15. Temperature sensor; 16. Humidity sensor; 17. Drain outlet; 171. Drain valve; 18. Insulation layer; 19. Reinforcement rib; 20. Liquid level sensor; 21. Water inlet pipe; 22. Solenoid valve. DETAILED DESCRIPTION

[0048] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0049] like Figure 1-2The figure is a schematic diagram of the structure of an integrated concrete curing system provided by the present invention, in which the structure includes: a curing box 10, a top cover plate 11, a support base 12 and a water adding device 13; a curing box is arranged on the support base, the curing box is a cubic structure, an opening is arranged on the top of the curing box, and a top cover plate is installed at the opening; a water inlet is arranged on the top cover plate, and a water adding device is installed at the water inlet; the water adding device includes a water tank body 131, a water tank baffle and a spraying system 133, and the water tank body is fixedly installed at the upper end of the top cover plate at the water inlet; the bottom of the water tank body is connected to the spraying system, and the spraying system extends to the inside of the curing box; a heating plate 14 is arranged at the bottom end of the interior of the curing box, and the heating plate is connected to an external power supply through a wire; a temperature sensor 15 and a humidity sensor 16 are arranged on one side wall of the curing box, and the temperature sensor and the humidity sensor both pass through the side wall of the curing box and extend to the inside of the curing box; a drain outlet 17 is arranged at the bottom of the other side wall of the curing box, and a drain valve 171 is installed at the drain outlet.

[0050] This integrated concrete curing system has the following advantages: 1) The closed design can accurately control the curing environment and reduce the influence of external factors; 2) The high degree of automation reduces manual intervention and improves the consistency of curing quality; 3) Multi-sensor real-time monitoring ensures accurate control of the curing process; 4) Modular design facilitates maintenance and upgrading; 5) Data recording function is conducive to the analysis and optimization of the curing process; 6) Energy saving and environmental protection, reducing the waste of energy and water resources through precise control. This system is suitable for the standardized curing of various concrete test blocks and can be widely used in construction engineering quality inspection, scientific research institutes and concrete production enterprises.

[0051] Among them, in the above technical scheme, the supporting base includes a bottom plate, on which a front supporting frame and a rear supporting frame are symmetrically arranged front and back; the maintenance box body is fixedly installed between the front supporting frame and the rear supporting frame; a control box is also fixed on the bottom plate, and a control chip is installed in the control box, and the control chip is electrically connected to the temperature sensor, humidity sensor, heating plate, water adding device and drain valve.

[0052] Furthermore, in the above technical solution, the spray system includes a main pipe 1331 and multiple branch pipes 1332, the main pipe is connected to the top cover plate, and the multiple branch pipes are evenly distributed on the inner side of the top of the top cover plate; each branch pipe is provided with multiple atomizing nozzles 1333 for evenly spraying water mist; the spray system also includes a water pump 1334, which is installed between the top cover plate and the main pipe to provide water pressure.

[0053] Furthermore, in the above technical solution, the top cover is arc-shaped and fits tightly with the opening of the maintenance box through a sealing ring to form a completely sealed cubic structure; an observation window is provided on the top cover, and the observation window is made of high-temperature resistant glass material to facilitate observation of the internal conditions of the maintenance box; a plurality of evenly distributed bolt holes are provided on the edge of the top cover, and the top cover is detachably connected to the maintenance box through bolts.

[0054] Furthermore, in the above technical solution, the heating plate adopts electric heating wire heating, and the electric heating wire is evenly distributed on the surface of the heating plate in a serpentine shape; the surface of the heating plate is covered with a corrosion-resistant coating to prevent the concrete from corroding the heating plate; an insulation layer 18 is provided between the heating plate and the inner wall of the curing box, and the insulation layer is made of ceramic fiber material to improve the heating efficiency and prevent heat loss.

[0055] Furthermore, in the above technical solution, both the temperature sensor and the humidity sensor are digital sensors with high precision and fast response characteristics; the measuring range of the temperature sensor is 0 to 100 degrees Celsius, with an accuracy of plus or minus 0.5 degrees Celsius; the measuring range of the humidity sensor is 0 to 100 percent relative humidity, with an accuracy of plus or minus 3 percent relative humidity; the temperature sensor and the humidity sensor are both connected to the side wall of the maintenance box through a waterproof joint to ensure the accuracy of the measurement data and the sealing of the system.

[0056] Furthermore, in the above technical solution, the drain outlet is located near one side of the bottom of the maintenance box, and the inner diameter of the drain outlet is 30 mm; the drain valve is an electric ball valve structure, the valve body is made of stainless steel, and the valve stem is made of a polytetrafluoroethylene sealing ring to ensure long-term use without leakage; the drain valve is driven by a motor, and the motor is electrically connected to the control chip to achieve automatic control.

[0057] Furthermore, in the above technical solution, a plurality of evenly distributed reinforcing ribs 19 are provided on the inner wall of the curing box, and the reinforcing ribs are distributed in a grid shape to enhance the structural strength of the curing box; the inner wall of the curing box is also coated with an anti-corrosion coating, and the anti-corrosion coating is made of epoxy resin material, which can effectively prevent the corrosion of the curing box by concrete and extend the service life of the system; the outer wall of the curing box is provided with an insulation layer, and the insulation layer is made of polyurethane foam material with a thickness of 50 mm to reduce heat loss and improve the curing efficiency.

[0058] Furthermore, in the above technical solution, a liquid level sensor 20 is provided on the water tank body for monitoring the amount of water in the water tank; a water inlet pipe 21 is provided on the water tank body, and a solenoid valve 22 is installed on the water inlet pipe, and the solenoid valve is electrically connected to the control chip; when the liquid level sensor detects that the water amount is lower than a preset value, the control chip controls the solenoid valve to open and automatically replenish the water.

[0059] like Figure 3As shown, in the above technical solution, a curing control module is provided in the control chip, and the curing control module is used to control the temperature, humidity and water supply during the concrete curing process; the curing control module is used to perform the following steps:

[0060] S10, receiving temperature data and humidity data collected by the temperature sensor and the humidity sensor;

[0061] S20, judging whether the current maintenance environment meets the preset maintenance conditions according to the received temperature data and humidity data;

[0062] S30, if the current curing environment does not meet the preset curing conditions, adjusting the heating power of the heating plate or controlling the water adding device to add water;

[0063] S40, adjusting the heating power of the heating plate and the water supply of the water adding device according to the preset curing time curve;

[0064] S50, monitoring the temperature change rate and humidity change rate during the maintenance process, and if the change rate exceeds a preset threshold, adjusting the heating power or water supply accordingly;

[0065] S60, recording temperature data, humidity data, heating power data and water supply data during the maintenance process to form a maintenance process data curve;

[0066] S70, dynamically adjust subsequent maintenance parameters according to the maintenance process data curve to ensure the stability of the maintenance effect;

[0067] S80. During the maintenance process, regularly check the water accumulation in the maintenance box and start the drain valve to drain water when necessary;

[0068] S90: When the curing time reaches the preset value, the heating plate is controlled to stop heating, the water adding device stops supplying water, and the curing process ends.

[0069] Specifically, step S10 includes:

[0070] Step 101, initialize the temperature sensor and humidity sensor, and set the sampling frequency to once per minute; Step 102, the temperature sensor adopts the thermocouple principle to convert the temperature change into a voltage signal, and the humidity sensor adopts the capacitive principle to convert the humidity change into a capacitance value change; Step 103, the analog-to-digital converter converts the analog signal into a digital signal; Step 104, the control chip reads the digital signal through the serial communication protocol (I2C or SPI); Step 105, the control chip uses a moving average filtering algorithm to filter the read temperature data and humidity data H to eliminate noise and improve data accuracy; Step 106, the accuracy of the temperature data is ±0.5℃, and the accuracy of the humidity data is ±3%RH.

[0071] Specifically, the specific steps of step S20 include: step 201, reading the preset maintenance conditions from the database, including the target temperature T0 and the target humidity H0; step 202, calculating the deviation C between the current environmental conditions and the preset conditions, and the calculation formula is: Wherein T is the current temperature (°C), H is the current relative humidity (%); Step 203, compare the calculated deviation C with the preset maximum allowable deviation threshold δ, if C≤δ, it is considered that the current maintenance environment meets the preset conditions, otherwise it is considered that it does not meet the preset conditions; Step 204, store the judgment result in a temporary variable for use in subsequent steps.

[0072] Specifically, the specific steps of step S30 include: step 301, according to the judgment result of S20, determine whether environmental adjustment is required; step 302, if adjustment is required, respectively calculate the temperature deviation ΔT=T0-T and the humidity deviation ΔH=H0-H; step 303, use the PID control algorithm to adjust the heating power P of the heating plate, and the output formula of the PID controller is: Where P0 is the initial heating power, k p , k i , k d are proportional, integral and differential coefficients respectively; Step 304, using PD control algorithm to adjust the water supply Q of the water adding device, the output formula of PD controller is: Wherein Q0 is the initial water supply, α is the proportional coefficient, and β is the differential coefficient; Step 305, output the calculated heating power P and water supply Q to the corresponding execution device.

[0073] Specifically, the specific steps of step S40 include: step 401, reading the preset curing time curve parameters from the database; step 402, calculating the theoretical heating power P according to the current curing time t; t And theoretical water supply Q t , the formulas are: P t =P max ·e -λt sin(ωt+φ) and Q t =Q max ·(1-e -μt )·cos(vt+ψ), where P max , λ, ω, φ and Q max , μ, v, ψ are preset parameters; Step 403, compare the theoretical value with the current actual value, and calculate the adjustment amount ΔP = P t -P and ΔP = Q t -Q; Step 404, using a fuzzy control algorithm to optimize the adjustment amount, and applying the optimized adjustment amount to the heating plate and the water adding device.

[0074] Specifically, the specific steps of step S50 include: step 501, calculating the temperature change rate and humidity change rate in and Calculated using the central difference method: Δt is the sampling time interval; Step 502, the calculated change rate R T and R H With the preset threshold R T,max and R H,max Compare; Step 503, if R T >R T,max or R H >R H,max , the emergency adjustment mechanism is activated, and the adaptive PID control algorithm is used to adjust the heating power for temperature exceeding the limit, and the fuzzy neural network control algorithm is used to adjust the water supply for humidity exceeding the limit; step 504, calculate the new PID control parameters and the weights of the fuzzy neural network, and applied to the heating plate and water adding device.

[0075] Specifically, the specific steps of step S60 include: step 601, setting the data recording frequency to record once every 5 minutes, and storing the collected temperature T, humidity H, heating power P and water supply Q data in the time series database; step 602, using the Fourier series expansion method to fit the temperature curve and humidity curve Wherein L is the total maintenance time, and N is the harmonic number; Step 603, use the cubic spline interpolation method to smooth the heating power and water supply data to obtain a continuous curve; Step 604, visualize the fitted temperature, humidity, heating power and water supply curves to generate a maintenance process data chart.

[0076] Specifically, the specific steps of step S70 include: step 701, statistically analyzing the maintenance process data to calculate the mean, standard deviation, skewness and kurtosis of temperature and humidity; step 702, using the EWMA method to predict the temperature and humidity trends in the short term in the future: t =αX t +(1-α)S t-1 , where S t is the predicted value at time t, X t is the actual value at time t, and α is the smoothing coefficient; Step 703, use the DTW algorithm to compare the similarity between the actual maintenance curve and the ideal curve, and calculate the DTW distance; Step 704, if the DTW distance exceeds the preset threshold, dynamically adjust the preset temperature and humidity And use genetic algorithm to optimize the PID controller parameter k p , k i , k d ; Step 705, apply the optimized parameters to the subsequent maintenance process.

[0077] Specifically, the specific steps of step S80 include: Step 801, establishing a moisture balance model in the curing box: Where V water is the volume of accumulated water, Q t is the water supply at time t, E t is the evaporation at time t, V absorbed is the water absorption of concrete; Step 802, using the numerical integration method to calculate the integral of water supply and evaporation, and through the empirical formula E t =k e ·A·(e s -e a ) Estimated evaporation E t , where k e is the evaporation coefficient, A is the water surface area, e s is the saturated water vapor pressure, e a is the actual water vapor pressure; Step 803, the calculated water volume V water With the preset threshold V threshold For comparison, if V water >V threshold , then start the drainage program; Step 804, control the drainage valve to open, and use the proportional control algorithm to adjust the drainage rate V drain =V water -V threshold ; Step 805, record the relevant information of the drainage event and store it in the database.

[0078] Specifically, the specific steps of step S90 include: step 901, compare the current curing time t with the preset curing time T, and when t≥T, enter the curing end procedure; step 902, use the ramp function to gradually reduce the heating power And the exponential function gradually reduces the water supply Q(t) = Q0·e -k(t-T) , where ΔT is the cooling time and k is the attenuation coefficient; Step 903, monitor the temperature and humidity changes in the maintenance box to ensure that they decrease slowly, and adjust the parameters of the ramp function and exponential function when necessary; Step 904, when the temperature and humidity reach the ambient temperature and humidity, completely turn off the heating plate and the water adding device; Step 905, generate a maintenance report, including the total maintenance time, temperature and humidity change curve, energy consumption statistics, abnormal event records and other information, and save it to the database.

[0079] The specific formula and its parameters are described in detail below:

[0080] In step S20, the formula for determining whether the current maintenance environment meets the preset maintenance conditions can be expressed as follows:

[0081]

[0082] Where C is the deviation between the current environmental conditions and the preset conditions; T is the current temperature (°C); T0 is the preset temperature (°C); H is the current relative humidity (%); H0 is the preset relative humidity (%); δ is the maximum allowable deviation threshold.

[0083] Parameter acquisition method: T and H are obtained by real-time measurement of temperature sensor and humidity sensor; T0 and H0 are pre-set values ​​according to concrete mix ratio and curing requirements, usually T0 ranges from 20 to 25°C , The range of H0 is 90~98%; δ is determined according to the requirements of maintenance accuracy, and the general value range is 2~5.

[0084] In step S30, the formula for adjusting the heating power of the heating plate can be expressed as follows:

[0085]

[0086] Where, is the adjusted heating power (W); P0 is the initial heating power (W); k p , k i , k d are proportional, integral and differential coefficients respectively; t is time (s).

[0087] Parameter acquisition method: P0 is usually 500~1000W; k p , k i , k d It needs to be determined through PID controller debugging, generally k p Range is 10~50,k i The range is 0.1~1,k d The range is 1 to 10.

[0088] The formula for controlling the water supply of the water adding device can be expressed as follows:

[0089]

[0090] Where Q is the adjusted water supply (L / min); Q0 is the initial water supply (L / min); α is the proportional coefficient; β is the differential coefficient.

[0091] Parameter acquisition method: Q0 is usually taken as 0.1~0.5L / min ； α and β need to be determined through experiments. Generally, the range of α is 0.01 to 0.1, and the range of β is 0.001 to 0.01.

[0092] In step S40, the formula for adjusting the heating power and water supply according to the preset curing time curve can be expressed as follows:

[0093] P t =P max ·e -λt sin(ωt+φ);Q t =Q max 1-e -μt )·cos(vt+ψ);

[0094] Where, P t is the heating power at time t (W); P max is the maximum heating power (W); λ is the attenuation coefficient; ω is the angular frequency; φ is the phase; Q t is the water supply at time t (L / min); Q max is the maximum water supply (L / min); μ is the growth coefficient; v is the angular frequency; ψ is the phase.

[0095] Parameter acquisition method: P max and Q max Determined according to the size of the maintenance box, generally P max 1000~2000W,Q max 0.5~1L / min; λ, ω, φ, μ, v, ψ need to be obtained by fitting experimental data, usually λ and μ range from 0.001~0.01 , The range of ω and v is 0.1~1, and the range of φ and ψ is 0~2π.

[0096] In step S50, the formula for monitoring the temperature change rate and humidity change rate can be expressed as follows:

[0097]

[0098] In the formula, R T is the temperature change rate (℃ / min); R H is the humidity change rate (% / min); R T,max is the maximum allowable temperature change rate (℃ / min); R H,max is the maximum allowable humidity change rate (% / min).

[0099] Parameter acquisition method: R T,max and R H,max Determined according to the concrete curing requirements, generally R T,max The value is 0.5~1℃ / min, R H,max The value is 1~2% / min.

[0100] In step S60, the formula for forming the maintenance process data curve can be expressed as follows:

[0101]

[0102] Where T(t) is the temperature function at time t; H(t) is the humidity function at time t; a0, a n 、b n ,c0,c n ,d n is the Fourier series coefficient; L is the period; N is the number of harmonics.

[0103] Parameter acquisition method: a0, a n 、b n ,c0,c n ,d n Obtained by Fourier transform of actual measured data; L is the total maintenance time; N is generally 5 to 10.

[0104] In step S70, the formula for dynamically adjusting the subsequent maintenance parameters can be expressed as follows:

[0105]

[0106] In the formula, and The preset temperature and humidity are adjusted; and is the preset temperature and humidity before adjustment; T and γ H is the learning rate; M is the number of samples; T i and H i is the actual temperature and humidity of the i-th sample.

[0107] Parameter acquisition method: γ T and γ H It is an empirical parameter, and its general value range is 0.1~0.5; M is determined according to the data sampling frequency, and is usually 100~1000.

[0108] In step S80, the formula for detecting the water accumulation in the curing box can be expressed as follows:

[0109]

[0110] Where, V water is the volume of accumulated water (L); Q t is the water supply at time t (L / min); E t is the evaporation rate at time t (L / min); V absorbed is the water absorption of concrete (L).

[0111] Parameter acquisition method: Et It can be determined experimentally or estimated using empirical formulas; V absorbed It can be calculated based on concrete mix ratio and curing time.

[0112] When V water When the preset threshold is exceeded, the drain valve is activated to drain water. drain It can be expressed as:

[0113] V drain =V water -V threshold ;

[0114] Where, V threshold is the water accumulation threshold (L), which is usually taken as 1-2% of the bottom area of ​​the curing box.

[0115] The integrated concrete curing system provided by the present invention mainly includes core components such as a curing box, a top cover plate, a support base and a water adding device. The curing box is made of 304 stainless steel material, has good corrosion resistance and strength, and has a cubic structure with an outer dimension of 1200mm×1200mm×1200mm. The box wall thickness is 5mm to ensure sufficient structural strength. The inner wall of the curing box is provided with a plurality of evenly distributed reinforcing ribs, which are distributed in a 50mm×50mm grid shape, further enhancing the structural strength of the box. The inner wall is coated with an epoxy resin anti-corrosion coating (model: AkzoNobel Interline984) with a thickness of 0.3mm, which can effectively prevent the corrosion of the box by concrete. The outer wall of the box is provided with a 50mm thick polyurethane foam insulation layer (thermal conductivity ≤0.024W / (m·K)) to reduce heat loss and improve curing efficiency. A 1100mm×1100mm opening is provided on the top of the curing box for placing concrete test blocks to be cured.

[0116] The top cover is made of the same 304 stainless steel as the curing box, with an arc-shaped design, a radius of 1500mm and a thickness of 8mm. There are 12 evenly distributed M10 bolt holes on the edge of the cover, which are detachably connected to the curing box through bolts. A 5mm thick silicone sealing ring is provided between the cover and the box opening to ensure good sealing. A circular observation window with a diameter of 300mm is provided in the center of the top cover, which is made of 10mm thick high-temperature resistant tempered glass (temperature range: -40℃ to 300℃) to facilitate observation of the internal conditions of the box. There is also a water inlet with a diameter of 100mm on the top cover for installing a water adding device.

[0117] The support base consists of a bottom plate, a front support frame and a rear support frame. The bottom plate is made of 10mm thick Q235 steel plate with a size of 1500mm×1500mm. The surface is rust-proofed and sprayed with epoxy resin paint. The front and rear support frames are made of 50mm×50mm×4mm square steel pipes with a height of 300mm and are fixed to the bottom plate by welding. The maintenance box is fixed between the front and rear support frames with M12 bolts. A 400mm×300mm×200mm stainless steel control box is also fixed on the bottom plate, which is equipped with a control chip (model: STM32F407ZGT6), relay module and other electrical components.

[0118] The water adding device includes a water tank body, a water tank baffle and a spray system. The water tank body is made of food-grade PP material, with a capacity of 50L and a size of 500mm×400mm×300mm. The water tank body is fixedly installed on the upper end of the top cover at the water inlet. The water tank baffle is made of 2mm thick 304 stainless steel plate to prevent water splashing. The bottom of the water tank body is connected to a spray system, including a main pipe and multiple branch pipes. The main pipe is a DN25 304 stainless steel pipe connected to the bottom of the water tank body. The 6 branch pipes are evenly distributed on the inner side of the top cover, and each branch pipe is equipped with 10 atomizing nozzles (model: 1 / 8" BSPF ultra-fine atomizing nozzle, spray particle size 20-100μm) for uniform spraying of water mist. The spray system also includes a small water pump (model: Grundfos CM3-4 ARAE-AVBE), with a rated power of 0.46kW and a maximum flow rate of 4.5m 3 / h, installed between the water tank body and the main pipeline to provide water pressure.

[0119] A heating plate with a size of 1000mm×1000mm is installed at the bottom of the curing box. It adopts electric heating wire heating. The electric heating wire is made of nickel-chromium alloy, with a diameter of 0.8mm, a total length of 30m, a rated power of 3kW, and is evenly distributed on the surface of the heating plate in a serpentine shape. The surface of the heating plate is covered with a 0.5mm thick Teflon coating to prevent the corrosion of the heating plate by concrete. A 20mm thick ceramic fiber insulation layer (thermal conductivity ≤0.04W / (m·K)) is provided between the heating plate and the inner wall of the curing box to improve the heating efficiency and prevent heat loss. The heating plate is connected to the external power supply through a high-temperature resistant silicone wire, and the working voltage is 220V AC.

[0120] A temperature sensor and a humidity sensor are installed on one side wall of the curing box. The temperature sensor uses a PT100 platinum resistor (model: OMEGA PR-20-2-100-1 / 4-6-E), with a measurement range of 0 to 100°C and an accuracy of ±0.5°C. The humidity sensor uses a capacitive sensor (model: Honeywell HIH-4000-003), with a measurement range of 0 to 100%RH and an accuracy of ±3%RH. Both sensors are connected to the side wall of the curing box through a waterproof connector (protection level IP67) to ensure the accuracy of the measurement data and the sealing of the system.

[0121] A drain port with an inner diameter of 30mm is provided at the bottom of the other side wall of the maintenance box. An electric ball valve (model: Best Q911F-16P DN25) is installed at the drain port. The valve body is made of 304 stainless steel and the valve stem is made of polytetrafluoroethylene sealing ring to ensure long-term use without leakage. The ball valve is driven by a 24V DC motor, and the motor is electrically connected to the control chip to achieve automatic control.

[0122] An ultrasonic level sensor (model: E+H FMU30) is installed on the water tank body to monitor the amount of water in the water tank. A DN20 water inlet pipe is installed on the top of the water tank body. A solenoid valve (model: Parker 321H35) is installed on the water inlet pipe. The working voltage is 24V DC and it is electrically connected to the control chip. When the level sensor detects that the water volume is lower than the preset value (such as 20L), the control chip controls the solenoid valve to open and automatically replenish the water.

[0123] The control chip (STM32F407ZGT6) in the control box uses the ARM Cortex-M4 core, with a main frequency of 168MHz, built-in 1MB Flash and 192KB RAM, and has rich peripheral interfaces. The control chip communicates with the temperature sensor and humidity sensor through the RS485 interface to collect real-time data. The switch of the heating plate, water pump, solenoid valve and drain valve is controlled through the GPIO interface. The control chip is also connected to a 7-inch LCD touch screen (model: NXP i.MX6ULL) with a resolution of 800×480 to display the system operation status and parameter settings.

[0124] The curing control module built into the control chip is the core of the system, which is used to control the temperature, humidity and water supply during the concrete curing process. The curing control module uses a PID (proportional-integral-differential) control algorithm to dynamically adjust the heating power and water supply according to the preset curing curve and real-time feedback data. The system can store a variety of preset curing curves suitable for different types of concrete formulas. The curing control module also has a data recording function, which can store data such as temperature, humidity, heating power and water supply during the curing process in the built-in SD card for subsequent analysis and optimization.

[0125] The workflow of the system is as follows: First, the operator sets the curing parameters, including target temperature, humidity, curing time, etc., through the touch screen. Then the concrete test block is placed in the curing box and the top cover is closed. After the system is started, the control chip monitors the environmental conditions in the box in real time through the temperature sensor and humidity sensor. According to the preset curing curve, the control chip adjusts the power output of the heating plate and controls the working status of the water pump and the spray system to maintain an ideal curing environment. During the curing process, the system dynamically adjusts the control parameters according to the temperature change rate and humidity change rate to ensure the stability of the curing effect. If water accumulation is detected in the box, the system will automatically open the drain valve for drainage. When the water in the water tank is insufficient, the system will automatically replenish the water through the solenoid valve. During the entire curing process, the LCD screen displays the current temperature, humidity, remaining time and other information in real time. After the curing is completed, the system will automatically turn off the heating and water supply, and issue a prompt to notify the operator.

[0126] The specific implementation method of step S10 is to collect the temperature data and humidity data inside the curing box through the temperature sensor and the humidity sensor. First, the system initializes the temperature sensor and the humidity sensor, and sets the sampling frequency to 1 time per minute. Then, the temperature sensor adopts the thermocouple principle to convert the temperature change into a voltage signal; the humidity sensor adopts the capacitive principle to convert the humidity change into a capacitance value change. Next, the analog-to-digital converter converts the analog signal into a digital signal. After that, the control chip reads the digital signal through a serial communication protocol (such as I2C or SPI). Finally, the control chip filters the read data and uses a moving average filtering algorithm to eliminate noise and improve data accuracy. The accuracy of the temperature data is ±0.5°C, and the accuracy of the humidity data is ±3%RH. The purpose of this step is to obtain accurate temperature and humidity data to provide a basis for subsequent maintenance control.

[0127] The specific implementation of step S20 is to determine whether the current maintenance environment meets the preset maintenance conditions based on the received temperature data and humidity data. First, the system reads the preset maintenance conditions from the database, including the target temperature T0 and the target humidity H0. Usually, the value range of T0 is 20-25°C, and the value range of H0 is 90%-98%RH. Then, the system calculates the deviation C between the current environmental conditions and the preset conditions, and the calculation formula is: Where T is the current temperature (℃), and H is the current relative humidity (%). Next, the system compares the calculated deviation C with the preset maximum allowable deviation threshold δ. The value range of δ is usually 2 to 5, and the specific value is determined according to the maintenance accuracy requirements. If C≤δ, it is considered that the current maintenance environment meets the preset conditions; otherwise, it is considered that the preset conditions are not met. Finally, the system stores the judgment result in a temporary variable for use in subsequent steps. The purpose of this step is to evaluate the suitability of the current maintenance environment and provide a basis for subsequent control decisions.

[0128] The specific implementation of step S30 is to adjust the heating power of the heating plate or control the water adding device to add water when the current curing environment does not meet the preset curing conditions. First, the system determines whether environmental adjustment is required based on the judgment result of S20. If adjustment is required, the system will calculate the temperature deviation ΔT=T0-T and the humidity deviation ΔH=H0-H respectively. The system uses a proportional-integral-differential (PID) control algorithm to adjust the heating power of the heating plate. The output formula of the PID controller is: Where P is the adjusted heating power (W), P0 is the initial heating power (W), k p , k i , k d They are proportional, integral and differential coefficients respectively. P0 is usually 500~1000W; k p The value range of k is 10~50, i The value range of k is 0.1~1, d The value range is 1 to 10. Then, the system uses the proportional-differential (PD) control algorithm to adjust the water supply of the water adding device. The output formula of the PD controller is: Where Q is the adjusted water supply (L / min), Q0 is the initial water supply (L / min), α is the proportional coefficient, and β is the differential coefficient. Q0 is usually 0.1-0.5L / min; the value range of α is 0.01-0.1, and the value range of β is 0.001-0.01. Finally, the system outputs the calculated heating power and water supply to the corresponding execution equipment. The purpose of this step is to quickly adjust the maintenance environment through closed-loop control so that it approaches the preset conditions.

[0129] The specific implementation method of step S40 is to adjust the heating power of the heating plate and the water supply of the water adding device according to the preset curing time curve. First, the system reads the preset curing time curve parameters from the database. Then, the system adopts a nonlinear time-varying control strategy and calculates the theoretical heating power P according to the current curing time t. t And theoretical water supply Q t The calculation formula of heating power is: P t =Pmax ·e -λt sin(ωt+φ), where P max is the maximum heating power (W), λ is the attenuation coefficient, ω is the angular frequency, and φ is the phase. max The value range of is 1000~2000W, the value range of λ is 0.001~0.01, the value range of ω is 0.1~1, and the value range of φ is 0~2π. The calculation formula of water supply is: Q t =Q max ·(1-e -μt )·cos(vt+ψ), where Q max is the maximum water supply (L / min), μ is the growth coefficient, v is the angular frequency, and ψ is the phase. max The value range of is 0.5~1L / min, the value range of μ is 0.001~0.01, the value range of v is 0.1~1, and the value range of ψ is 0~2π. Then, the system compares the theoretical value with the current actual value and calculates the adjustment amount. For heating power, the adjustment amount ΔP=P t -P; for water supply, adjustment amount ΔQ = Q t -Q. Then, the system uses a fuzzy control algorithm to optimize the adjustment amount. The input of the fuzzy controller is the adjustment amount and the current environmental conditions, and the output is the optimized adjustment amount. Finally, the system applies the optimized adjustment amount to the heating plate and the water adding device. The purpose of this step is to achieve dynamic control of the curing process and ensure that the curing environment changes over time in accordance with the preset curve.

[0130] The specific implementation of step S50 is to monitor the temperature change rate and humidity change rate during the maintenance process. If the change rate exceeds the preset threshold, the heating power or water supply is adjusted accordingly. First, the system calculates the temperature change rate R T and humidity change rate R H The calculation formula is: and in and Calculated using the central difference method: Δt is the sampling time interval. Then, the system compares the calculated change rate with the preset threshold R T,max and R H,max For comparison. T,max The value range is 0.5~1℃ / min, R H,max The value range is 1~2%RH / min. T >R T,max or R H >R H,max, the system will start the emergency adjustment mechanism. For temperature exceeding the limit, the system uses the adaptive PID control algorithm to adjust the heating power. The parameters of the adaptive PID controller are dynamically adjusted according to the temperature change rate: Where γ is the learning rate, which ranges from 0.1 to 0.5. For humidity exceeding the limit, the system uses a fuzzy neural network control algorithm to adjust the water supply. The fuzzy neural network consists of a fuzzy layer, a rule layer, and an output layer, and continuously optimizes the control strategy through online learning. Finally, the system applies the adjusted control parameters to the heating plate and the water adding device. The purpose of this step is to prevent drastic fluctuations in the curing environment and ensure the stability of the curing process.

[0131] The specific implementation method of step S60 is to record the temperature data, humidity data, heating power data and water supply data during the maintenance process to form a maintenance process data curve. First, the system sets the data recording frequency, usually once every 5 minutes. Then, the system stores the collected temperature, humidity, heating power and water supply data in the time series database. Next, the system uses the Fourier series expansion method to fit the temperature and humidity curves. The temperature fitting formula is: The humidity fitting formula is: Among them, a0, a n 、b n ,c0,c n ,d n is the Fourier series coefficient, L is the total maintenance time, and N is the harmonic number, which is usually 5 to 10. The system uses the least squares method to determine the values ​​of each coefficient. Then, the system uses the cubic spline interpolation method to smooth the heating power and water supply data to obtain a continuous curve. The cubic spline interpolation function is a piecewise cubic polynomial: S i (t) = a i +b i (tt i )+c i (tt i ) 2 +d i (tt i ) 3 ,in i Indicates the interval number, a i 、b i 、c i ,d i are the unknown coefficients. The system determines these coefficients by solving a set of linear equations. Finally, the system visualizes the fitted temperature, humidity, heating power and water supply curves and generates a maintenance process data chart. The purpose of this step is to comprehensively record the maintenance process and provide data support for subsequent analysis and optimization.

[0132] The specific implementation method of step S70 is to dynamically adjust the subsequent maintenance parameters according to the maintenance process data curve to ensure the stability of the maintenance effect. First, the system performs statistical analysis on the maintenance process data and calculates the mean, standard deviation, skewness and kurtosis of temperature and humidity. Then, the system uses the exponentially weighted moving average (EWMA) method to predict the temperature and humidity trends in the short term. The EWMA formula is: t =αX t +(1-α)S t-1 , where S t is the predicted value at time t, X t is the actual value at time t, α is the smoothing coefficient, and its value range is 0.1 to 0.3. Then, the system uses the dynamic time warping (DTW) algorithm to compare the similarity between the actual maintenance curve and the ideal curve, and calculates the DTW distance between the two curves. If the DTW distance exceeds the preset threshold (usually 10% of the ideal curve length), the system will trigger the parameter adjustment mechanism. The system uses an online learning algorithm to dynamically adjust the preset temperature T0 and humidity H0. The adjustment formula is: Among them, γ T and γ H is the learning rate, ranging from 0.1 to 0.5; M is the number of samples, usually 100 to 1000. Then, the system uses genetic algorithm to optimize the PID controller parameter k p , k i , k d The fitness function of the genetic algorithm is the root mean square of the control error. The population size is set to 50, the number of iterations is 100, the crossover probability is 0.8, and the mutation probability is 0.1. Finally, the system applies the optimized parameters to the subsequent maintenance process. The purpose of this step is to continuously optimize the maintenance strategy and improve the consistency of the maintenance effect through adaptive control.

[0133] The specific implementation method of step S80 is to regularly detect the water accumulation in the curing box during the curing process, and start the drain valve to drain water when necessary. First, the system establishes a water balance model in the curing box: Where V water is the volume of water (L), Q t is the water supply at time t (L / min), E t is the evaporation rate at time t (L / min), V absorbed is the water absorption of concrete (L). Then, the system uses numerical integration methods (such as trapezoidal method) to calculate the integral of water supply and the integral of evaporation. Evaporation E t Estimated by empirical formula: E t =k e ·A·(e s -e a ), where k eis the evaporation coefficient (usually 0.1-0.2 mm / hPa / h), A is the water surface area (m 2 ),e s is the saturated water vapor pressure (hPa), e a is the actual water vapor pressure (hPa). Concrete water absorption V absorbed Calculated by concrete mix ratio and curing time: V absorbed =m c ·w / c·1-e -kt ), where m c is the cement mass (kg), w / c is the water-cement ratio, k is the water absorption rate coefficient (usually 0.1 to 0.3 h -1 ), t is the curing time (h). Then, the system calculates the accumulated water volume V water With the preset threshold V threshold For comparison. threshold The value is usually 1% to 2% of the bottom area of ​​the curing box. water >V threshold , the system will start the drainage procedure. Discharge volume V drain The calculation formula is: V drain =V water -V threshold . Then, the system controls the drainage valve to open and uses a proportional control algorithm to adjust the drainage rate to prevent drastic fluctuations in environmental parameters during the drainage process. After the drainage is completed, the system updates the parameters in the water balance model. Finally, the system records the drainage events, including drainage time, drainage volume, and drainage duration, and stores this information in the database. The purpose of this step is to maintain a suitable humidity environment in the curing box to prevent excessive water accumulation from affecting the quality of concrete curing.

[0134] The specific implementation of step S90 is that when the curing time reaches the preset value, the heating plate is controlled to stop heating, the water supply device stops supplying water, and the curing process ends. First, the system compares the current curing time t with the preset curing time T. When t ≥ T, the system enters the curing end procedure. Then, the system uses a ramp function to gradually reduce the heating power to avoid a sudden drop in temperature. The ramp function is: Where P0 is the initial power, ΔT is the cooling time (usually 30 minutes). At the same time, the system gradually reduces the water supply, and the water supply reduction curve is an exponential function: Q(t) = Q0·e -k(t-T), where Q0 is the initial water supply and k is the attenuation coefficient (usually 0.1min-1). Next, the system monitors the temperature and humidity changes in the curing box to ensure that they decrease slowly. If it is detected that the temperature or humidity decrease rate exceeds the preset threshold (temperature: 0.5℃ / min, humidity: 1%RH / min), the system will automatically adjust the parameters of the ramp function and exponential function to ensure a smooth transition of environmental parameters. Then, the system waits for the temperature and humidity in the curing box to reach the ambient temperature and humidity, and completely turns off the heating plate and water adding device. Finally, the system generates a maintenance report, including total maintenance time, temperature and humidity change curves, energy consumption statistics, abnormal event records and other information. The system saves the maintenance report to the database and can optionally send it to a designated mailbox or print it. The purpose of this step is to end the maintenance process safely and orderly, while providing complete process data for subsequent maintenance quality evaluation.

[0135] Embodiment 1:

[0136] This embodiment describes the specific application of the integrated concrete curing system in a high-speed railway platform project. The high-speed railway platform project is located in a coastal city with high temperature and heavy rain, which places high demands on concrete curing. The construction phase of the project coincides with summer, with ambient temperatures as high as 35-40°C and relative humidity fluctuating between 70-80%, which is extremely unfavorable for the early curing of concrete. In order to ensure the quality of concrete, the engineering team decided to use the integrated concrete curing system of the present invention for on-site curing.

[0137] 1. System Configuration

[0138] According to the project requirements, a cubic curing box with an internal size of 1.5m×1.5m×1.5m was selected. The curing box is made of 304 stainless steel, and the inner wall is coated with a 0.5mm thick epoxy resin anti-corrosion coating. The outer wall of the box is covered with a 50mm thick polyurethane foam insulation layer to improve the insulation effect. A 2000W electric heating wire heating plate is installed at the bottom of the curing box, and the surface of the heating plate is covered with a 0.2mm thick corrosion-resistant coating. A 20mm thick ceramic fiber insulation layer is set between the heating plate and the inner wall of the box.

[0139] The top cover adopts an arc design, and the highest point is 15cm higher than the edge of the box. A circular observation window with a diameter of 30cm is installed on the cover, which is made of 10mm thick tempered high-temperature resistant glass. There are 16 M10 bolt holes evenly distributed on the edge of the cover for detachable connection with the box. A 5mm thick silicone sealing ring is used between the cover and the box to ensure sealing.

[0140] The water adding device includes a water tank body with a capacity of 100L, and an ultrasonic level sensor is installed in the water tank. The spray system consists of a main pipe with a diameter of 25mm and 8 branch pipes with a diameter of 15mm. Ten atomizing nozzles are evenly installed on each branch pipe, and the nozzle aperture is 0.5mm. The water pump uses a centrifugal pump with a power of 200W, a maximum head of 5m, and a maximum flow of 60L / min.

[0141] The temperature sensor uses a PT100 platinum resistor with a measurement range of 0-100°C and an accuracy of ±0.5°C. The humidity sensor uses a capacitive sensor with a measurement range of 0-100%RH and an accuracy of ±3%RH. Both sensors are connected to the box through an IP67 waterproof connector.

[0142] The inner diameter of the drain port is 30mm, and a DN25 electric ball valve is installed. The valve body is made of 304 stainless steel and the sealing material is PTFE. A 32-bit ARM Cortex-M4 microcontroller is installed in the control box as the control chip, with a main frequency of 168MHz, built-in 512KB Flash and 128KB RAM.

[0143] 2. Maintenance process

[0144] The maintenance object this time is C50 high performance concrete, and the mix ratio is shown in the following table:

[0145] raw materials <![CDATA[Dosage (kg / m 3 )]]> cement 410 Fly ash 70 Mineral powder 50 sand 710 gravel 1050 water 160 Water reducing agent 5.3

[0146] According to the concrete mix ratio and engineering requirements, the curing parameters are set as follows: curing temperature 25±2℃, relative humidity 95±3%, and curing time 7 days.

[0147] Before the curing process begins, first clean the inside of the curing box and lay a 5mm thick plastic film on the bottom to prevent direct contact between the concrete and the box. Place the newly poured concrete test blocks (size 150mm×150mm×150mm) into the curing box, keeping a 50mm gap between the test blocks to ensure full contact with the curing environment.

[0148] After starting the system, the control chip first reads the data of the temperature sensor and humidity sensor. The initial temperature is 36.5℃ and the relative humidity is 75.8%. The system determines that the current environment does not meet the preset maintenance conditions and immediately starts the adjustment process.

[0149] The heating plate starts working with an initial power of 500W, and the spray system starts spraying water at a flow rate of 0.5L / min. The control chip collects sensor data every 10 seconds and adjusts the heating power and water supply according to the PID algorithm. After about 30 minutes of adjustment, the temperature inside the box dropped to 26.8℃ and the relative humidity rose to 93.5%.

[0150] During the next 7-day curing period, the system continuously monitors and adjusts the curing environment. Every 6 hours, the system fine-tunes the target temperature and humidity according to the preset curing time curve. For example, on the 3rd day, the target temperature is adjusted to 24.5°C and the relative humidity is adjusted to 96%. This dynamic adjustment helps simulate the slow changes in the natural curing environment and is conducive to the release of internal stress in concrete.

[0151] During the maintenance process, the system records detailed environmental parameter data. The following are some data records at key time points:

[0152]

[0153] During the maintenance process, the system conducts a water accumulation test every day. Due to the high humidity and low evaporation, it was detected on the third day that the water accumulated at the bottom of the box reached 2.5L. The system automatically opened the drain valve to discharge 2L of water and retained 0.5L to maintain the humidity at the bottom.

[0154] During the maintenance period, the staff checked the concrete surface condition through the observation window every day to ensure that there were no shrinkage cracks. At the same time, the maintenance parameters were monitored in real time through the display screen of the control box. The system operated stably without any abnormalities.

[0155] 3. Maintenance effect evaluation

[0156] After the curing, the test blocks were taken out for various performance tests. At the same time, in order to compare the curing effect, another test block with the same ratio was made and cured for 7 days in the field environment using the traditional wet cloth covering curing method. The test results of the two groups of test blocks are shown in the following table:

[0157]

[0158] From the test results, it can be seen that the test blocks cured by the integrated concrete curing system are superior to the traditional wet cloth curing method in all performance indicators. Especially in terms of early strength development and durability indicators, the integrated system curing effect is more significant. This is mainly due to the system's ability to provide a stable and controllable curing environment, which effectively avoids the uneven curing problem caused by environmental changes in traditional curing methods.

[0159] 4. Economic Benefit Analysis

[0160] Although the initial investment of the integrated concrete maintenance system is high, its economic benefits are significant in the long run. Taking this project as an example, the high-speed railway platform needs to maintain a total of about 1000m 3Concrete. Using the traditional wet cloth curing method, two workers are needed every day for curing operations, with a salary of 200 yuan per day for each worker. The curing period is 7 days, and the labor cost is 2,800 yuan. In addition, it is necessary to consider the material cost of wet cloth, plastic film, etc., which is about 1,000 yuan, as well as the cost of repairs and rework that may be caused by improper curing, which is conservatively estimated to be 1% of the total cost, about 10,000 yuan.

[0161] In contrast, the one-time investment cost of the integrated concrete curing system is about 50,000 yuan (including 5 sets of curing boxes and supporting equipment). Only one worker is needed every day for monitoring and simple operations, and the labor cost for 7 days is 1,400 yuan. The cost of electricity and water is about 500 yuan. The system can be reused, and based on 5-year depreciation, the equipment cost shared by this project is about 2,000 yuan.

[0162] Comprehensive calculation shows that the total cost of the traditional maintenance method is about 13,800 yuan, while the total cost of the integrated system is about 3,900 yuan. Although the initial investment of the integrated system is high, it has saved 9,900 yuan in this project. Considering that the system can be reused, the long-term economic benefits are more significant. In addition, the concrete maintained by the integrated system is of higher quality, which can reduce the subsequent maintenance costs and further improve the economic benefits.

[0163] 5. Environmental benefit analysis

[0164] The integrated concrete curing system is not only economically advantageous, but also has obvious advantages in environmental protection. The traditional wet cloth curing method requires a lot of water resources, and it is difficult to accurately control the amount of water used, which often results in a waste of water resources. The integrated system greatly reduces water resource consumption by accurately controlling the spraying volume and recycling water. In this project, the traditional method is expected to require about 30m 3 , while the integrated system consumes only about 5m 3 Water, water saving rate is as high as 83%.

[0165] In addition, plastic films are often used in traditional maintenance processes. These disposable plastic products will generate a large amount of solid waste that is difficult to degrade. The integrated system completely avoids this problem and reduces environmental pollution.

[0166] In terms of energy consumption, although the integrated system needs to consume electricity, the actual energy consumption is relatively low due to its precise temperature control system and good thermal insulation performance. In this project, the system's total energy consumption for 7 days is about 180kWh, which is equivalent to the electricity consumption of an average household in a week. Considering that the system significantly improves the quality of concrete, from the perspective of the entire life cycle, it actually reduces the overall energy consumption of concrete structures.

[0167] 6.Technological innovation

[0168] The integrated concrete curing system in this embodiment embodies multiple technical innovations:

[0169] (1) Integrated design: The system integrates temperature and humidity control, water supply, heating, data acquisition and other functions in a closed box, realizing integrated management of the maintenance process.

[0170] (2) Precise control: Through high-precision sensors and PID control algorithms, the system can accurately control the temperature and humidity of the maintenance environment, with errors within the range of ±0.5℃ and ±1%RH.

[0171] (3) Intelligent management: The system automatically adjusts parameters according to the preset maintenance curve and can self-optimize according to the actual maintenance effect, reducing human intervention.

[0172] (4) Modular structure: The system adopts modular design, which is easy to maintain and upgrade. For example, the water tank, heating plate, control box, etc. are all detachable modules, which are easy to replace and repair.

[0173] (5) Data traceability: The system records all parameters during the maintenance process, providing detailed data support for quality control and subsequent research.

[0174] Specifically, the principle of the present invention is: the integrated concrete curing system of the present invention is mainly composed of a curing box, a support base, a water supply device and a control system. Among them, the curing box is a closed cubic structure, with a temperature sensor and a humidity sensor inside, which are used to monitor environmental parameters in real time; a heating plate is provided at the bottom of the curing box, which can provide the required heating power through electric heating wire heating; a spray system is provided on the top, which is composed of a water tank body, a water pump and multiple nozzles, which can evenly spray water mist into the box to replenish water; the support base provides a stable installation platform for the entire system. The core of the control system is a control chip, which is responsible for collecting data from various sensors, executing control algorithms and driving actuators such as heating plates and spray systems to achieve precise control of curing environmental parameters.

[0175] During the curing process, the control system first collects real-time data from the temperature sensor and humidity sensor according to the preset temperature and humidity target values, and calculates the deviation between the current environmental conditions and the preset conditions. If the deviation exceeds the allowable range, the control system will automatically adjust the heating power of the heating plate and the water supply of the spray system to reduce the temperature and humidity deviation, so that the curing environment gradually approaches the preset optimal curing conditions. During this process, the control system will also monitor the rate of change of temperature and humidity. Once it is found that the change is too fast and may have an adverse effect on the concrete, emergency measures will be taken immediately to adjust it. At the same time, the system will record the temperature and humidity data, energy consumption data, etc. of the entire curing process in real time to form a complete curing process curve, which provides a basis for subsequent analysis and optimization.

[0176] In addition, the system is equipped with a water level monitoring and drainage mechanism. When there is too much water inside the box, the control system will automatically start the drainage valve to drain the water and keep the humidity inside the box within a reasonable range. At the same time, the system will dynamically adjust the amount of water added according to the water balance model to ensure the balance between water supply and evaporation, and avoid excessive or low humidity.

[0177] It is worth mentioning that the curing box of the present invention adopts an optimized structural design. The inner wall of the box is provided with grid-shaped reinforcement ribs to improve the structural strength; the inner wall is coated with a corrosion-resistant protective coating to extend the service life; the outer wall is provided with an insulation layer to reduce heat loss; the top cover adopts a sealing design to ensure good sealing. These design measures not only improve the reliability of the system, but also ensure the stability and consistency of the curing process.

[0178] In summary, the integrated concrete curing system of the present invention realizes precise control of curing environment parameters through advanced temperature and humidity monitoring and intelligent control technology. The system integrates key functional modules such as heating, water addition, and drainage, and can automatically complete the entire curing process, greatly improving work efficiency. At the same time, the system collects and analyzes data from the entire process, dynamically optimizes the curing strategy, and ensures the stability and reliability of the curing quality. These innovative designs give the system of the present invention significant technical advantages in the field of concrete curing, and provide an advanced and reliable solution for large-scale engineering projects.

Claims

1. An integrated concrete curing system, characterized in that , including: a maintenance box, a top cover, a support base and a water adding device; a maintenance box is arranged on the support base, the maintenance box is a cubic structure, an opening is arranged on the top of the maintenance box, and a top cover is installed at the opening; a water inlet is arranged on the top cover, and a water adding device is installed at the water inlet; the water adding device includes a water tank body, a water tank baffle and a spray system, the water tank body is fixedly mounted on the upper end of the top cover at the water inlet; the bottom of the water tank body is connected to the spray system, and the spray system extends to the inside of the maintenance box; a heating plate is arranged at the bottom end of the inside of the maintenance box, and the heating plate is connected to an external power supply through a wire; a temperature sensor and a humidity sensor are arranged on one side wall of the maintenance box, and the temperature sensor and the humidity sensor both pass through the side wall of the maintenance box and extend to the inside of the maintenance box; a drain outlet is arranged at the bottom of the other side wall of the maintenance box, and a drain valve is installed at the drain outlet.

2. The integrated concrete curing system according to claim 1 is characterized in that The support base includes a bottom plate, on which a front support frame and a rear support frame are symmetrically arranged front and back; the maintenance box is fixedly installed between the front support frame and the rear support frame; a control box is also fixed on the bottom plate, and a control chip is installed in the control box, and the control chip is electrically connected to the temperature sensor, the humidity sensor, the heating plate, the water adding device and the drain valve.

3. The integrated concrete curing system according to claim 2 is characterized in that The spray system includes a main pipeline and multiple branch pipelines. The main pipeline is connected to the top cover plate, and the multiple branch pipelines are evenly distributed on the inner side of the top of the top cover plate; each branch pipeline is provided with multiple atomizing nozzles for evenly spraying water mist; the spray system also includes a water pump, which is installed between the top cover plate and the main pipeline to provide water pressure.

4. The integrated concrete curing system according to claim 3 is characterized in that The top cover is arc-shaped and fits tightly with the opening of the maintenance box through a sealing ring to form a completely sealed cubic structure; an observation window is provided on the top cover, and the observation window is made of high-temperature resistant glass material to facilitate observation of the internal situation of the maintenance box; a plurality of evenly distributed bolt holes are provided on the edge of the top cover, and the top cover is detachably connected to the maintenance box through bolts.

5. The integrated concrete curing system according to claim 4 is characterized in that The heating plate adopts electric heating wire heating method, and the electric heating wire is evenly distributed on the surface of the heating plate in a serpentine shape; the surface of the heating plate is covered with a corrosion-resistant coating to prevent the concrete from corroding the heating plate; an insulation layer is provided between the heating plate and the inner wall of the curing box, and the insulation layer is made of ceramic fiber material to improve the heating efficiency and prevent heat loss.

6. The integrated concrete curing system according to claim 5 is characterized in that The temperature sensor and humidity sensor are both digital sensors with high precision and fast response characteristics; the measurement range of the temperature sensor is 0 to 100 degrees Celsius, with an accuracy of plus or minus 0.5 degrees Celsius; the measurement range of the humidity sensor is 0 to 100 percent relative humidity, with an accuracy of plus or minus 3 percent relative humidity; the temperature sensor and humidity sensor are both connected to the side wall of the maintenance box through a waterproof joint to ensure the accuracy of the measurement data and the sealing of the system.

7. The integrated concrete curing system according to claim 6 is characterized in that The drain outlet is located at one side of the bottom of the maintenance box, and the inner diameter of the drain outlet is 30 mm; the drain valve is an electric ball valve structure, the valve body is made of stainless steel, and the valve stem is made of polytetrafluoroethylene sealing ring to ensure long-term use without leakage; the drain valve is driven by a motor, and the motor is electrically connected to the control chip to realize automatic control.

8. The integrated concrete curing system according to claim 7 is characterized in that The inner wall of the maintenance box is provided with a plurality of evenly distributed reinforcing ribs, which are distributed in a grid shape to enhance the structural strength of the maintenance box; the inner wall of the maintenance box is also coated with an anti-corrosion coating, which uses epoxy resin material to effectively prevent concrete from corroding the maintenance box and extend the service life of the system; the outer wall of the maintenance box is provided with an insulation layer, which uses polyurethane foam material with a thickness of 50 mm to reduce heat loss and improve maintenance efficiency.

9. The integrated concrete curing system according to claim 8 is characterized in that The water tank body is provided with a liquid level sensor for monitoring the amount of water in the water tank; the water tank body is provided with a water inlet pipe, on which a solenoid valve is installed, and the solenoid valve is electrically connected to the control chip; when the liquid level sensor detects that the water amount is lower than a preset value, the control chip controls the solenoid valve to open and automatically replenish the water.

10. The integrated concrete curing system according to claim 9 is characterized in that The control chip is provided with a curing control module, which is used to control the temperature, humidity and water supply during the concrete curing process; the curing control module is used to perform the following steps: S10, receiving temperature data and humidity data collected by the temperature sensor and the humidity sensor; S20, judging whether the current maintenance environment meets the preset maintenance conditions according to the received temperature data and humidity data; S30, if the current curing environment does not meet the preset curing conditions, adjusting the heating power of the heating plate or controlling the water adding device to add water; S40, adjusting the heating power of the heating plate and the water supply of the water adding device according to the preset curing time curve; S50, monitoring the temperature change rate and humidity change rate during the maintenance process, and if the change rate exceeds a preset threshold, adjusting the heating power or water supply accordingly; S60, recording temperature data, humidity data, heating power data and water supply data during the maintenance process to form a maintenance process data curve; S70, dynamically adjust subsequent maintenance parameters according to the maintenance process data curve to ensure the stability of the maintenance effect; S80. During the maintenance process, regularly check the water accumulation in the maintenance box and start the drain valve to drain water when necessary; S90: When the curing time reaches the preset value, the heating plate is controlled to stop heating, the water adding device stops supplying water, and the curing process ends.

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