A high viscosity concrete vibrating system

Abstract

This invention provides a high-viscosity concrete vibration system, belonging to the field of concrete vibration technology. The high-viscosity concrete vibration system includes: a vibrating cylinder, a vibrating rod, a drive mechanism, a transmission mechanism, a fixing frame, a vibration damping component, an adjustment component, a control panel, and a sealing cover. The vibrating cylinder has a cylindrical structure with an opening at the top and a closed bottom. The vibrating rod is cylindrical with a diameter smaller than the inner diameter of the vibrating cylinder, and is vertically positioned inside the cylinder. The drive mechanism includes a motor, a motor base, and a power cord. The motor base is fixedly installed above the vibrating cylinder, and the motor is bolted to the base. The power cord is electrically connected to the motor. This invention effectively solves the problem that existing technologies cannot meet the vibration requirements of high-viscosity concrete.

Description

Technical Field

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

[0002] Concrete, as one of the most widely used basic materials in construction engineering, has a significant impact on the overall quality of the project. A crucial step in concrete construction is concrete vibration. Vibration effectively eliminates air bubbles in the concrete, promotes the full bonding of aggregates and paste, and improves the strength and density of the concrete.

[0003] Traditional concrete vibration relies primarily on manual operation, using handheld electric or gasoline-powered vibrators. This method is labor-intensive, prone to causing localized damage to the concrete, and unsuitable for vibrating large volumes of concrete. With the continuous development of construction engineering, automated vibration equipment has emerged, such as vibratory trolleys and vibratory beams. These devices use motors to drive the vibrating head back and forth across the concrete surface, effectively improving vibration efficiency. However, for some highly viscous concretes, the vibration effect of these devices is not ideal, often failing to completely eliminate air bubbles, and the concrete density cannot reach the desired level.

[0004] For highly viscous concrete, more effective vibration methods are usually required. A common approach is to use high-frequency vibratory compactors, which enhance the flowability of the concrete and promote the full removal of air bubbles. However, this type of equipment is complex in structure, expensive, and detrimental to the smoothness of the concrete surface. Another method is to use a mixing vibrator, which uses mixing blades to stir the concrete inside the vibratory drum, combined with the up-and-down movement of the vibrating rod, to improve the compaction effect. However, this type of equipment typically cannot precisely control the vibration parameters and is difficult to automatically optimize for different concrete characteristics.

[0005] In summary, existing concrete vibration technologies still have some problems and cannot fully meet the vibration requirements of high-viscosity concrete. Developing a high-viscosity concrete vibration system with a simple structure, good vibration effect, and automatic optimization of vibration parameters has become the technological development direction in this field. Summary of the Invention

[0006] This invention proposes a high-viscosity concrete vibration system, which has a simple structure and stable performance, and can effectively solve the problem that existing technologies cannot meet the vibration requirements of high-viscosity concrete.

[0007] This invention is implemented as follows:

[0008] This invention provides a high-viscosity concrete vibration system, comprising: a vibrating cylinder, a vibrating rod, a drive mechanism, a transmission mechanism, a fixing frame, a vibration damping component, an adjustment component, a control panel, and a sealing cover; the vibrating cylinder is cylindrical with an opening at the top and a closed bottom; the vibrating rod is cylindrical with a diameter smaller than the inner diameter of the vibrating cylinder, and is vertically positioned inside the vibrating cylinder; the drive mechanism includes a motor, a motor base, and a power cord, with the motor base fixedly mounted above the vibrating cylinder, the motor bolted to the motor base, and the power cord electrically connected to the motor; the transmission mechanism includes a drive gear, a rack, and a transmission shaft, with the drive gear fixedly mounted on the output shaft of the motor, the rack fixedly mounted on the upper end of the transmission shaft, the drive gear meshing with the rack, the lower end of the transmission shaft fixedly connected to the upper end of the vibrating rod, and the transmission shaft slidably connected to the vibrating cylinder; the fixing frame includes... The system includes a base, support columns, and a crossbeam. The base is a square flat plate, with the support columns vertically fixed at the four corners. The crossbeam is fixedly connected to the top of the four support columns. The shock absorption assembly includes a spring, a shock-absorbing pad, and a connecting plate. One end of the spring is fixedly connected to the base, and the other end is fixedly connected to the connecting plate. The shock-absorbing pad is positioned between the connecting plate and the bottom of the vibrating cylinder. The adjustment assembly includes an adjusting screw, an adjusting handwheel, and a fixing sleeve. The adjusting screw is vertically positioned, with its lower end fixedly connected to the outer wall of the vibrating cylinder. The upper end of the adjusting screw passes through a threaded hole on the crossbeam and is fixedly connected to the adjusting handwheel. The fixing sleeve is fitted onto the adjusting screw and fixedly connected to the crossbeam. The control panel is fixedly installed on one of the support columns and is electrically connected to the motor. The sealing cover is disc-shaped, with a diameter larger than the diameter of the opening of the vibrating cylinder. The sealing cover is rotatably connected to the top edge of the vibrating cylinder via a hinge.

[0009] The technical effects of the high-viscosity concrete vibration system provided by this invention are as follows: This invention proposes a high-viscosity concrete vibration system with simple structure and stable performance, which can effectively solve the problem that existing technologies cannot meet the vibration requirements of high-viscosity concrete.

[0010] First, this vibration system employs a unique vibration mechanism design. A vibrating rod is installed inside the vibrating cylinder, driven by a drive mechanism to reciprocate up and down, achieving effective vibration of the concrete. The inner wall of the vibrating cylinder has annular protrusions that cooperate with the annular grooves on the outer wall of the vibrating rod, effectively enhancing the vibration effect. Simultaneously, the bottom of the vibrating rod has a conical head, and the outer wall has spiral ridges, which further promote concrete flow and the removal of air bubbles.

[0011] Secondly, the system employs an optimized vibration damping mechanism design. The base is connected to the vibratory drum via springs and damping pads, effectively absorbing vibration impacts and protecting the equipment structure from damage. A limit ring is also included to restrict the horizontal displacement of the vibratory drum, further enhancing the system's stability.

[0012] Furthermore, the system is equipped with an intelligent control system. The vibration frequency and time can be adjusted via the control panel to meet the vibration requirements of concretes with varying viscosity. Simultaneously, the system has a built-in vibration optimization module that automatically adjusts vibration parameters based on the concrete's viscosity and liquid level to achieve optimal vibration results. This automatic optimization function is a first among existing vibration equipment.

[0013] In addition, the system also features a mixing function. Spiral mixing blades are installed below the sealed cover, which mix the concrete during vibration, further promoting the removal of air bubbles. Simultaneously, guide grooves are located inside the vibrating cylinder, which, in conjunction with the mixing blades, improve the fluidity of the concrete.

[0014] In summary, this high-viscosity concrete vibration system integrates multiple innovative technologies, effectively addressing the problem that existing vibration equipment cannot meet the vibration requirements of high-viscosity concrete. It not only provides excellent vibration results and is easy to operate, but also automatically adjusts vibration parameters according to actual conditions, significantly improving work efficiency. The application of this system will bring significant economic and social benefits to building construction projects.

[0015] Based on the above technical solution, the high-viscosity concrete vibration system of the present invention can be further improved as follows:

[0016] The inner wall of the vibrating cylinder is provided with multiple annular protrusions, which are evenly distributed along the axial direction of the vibrating cylinder; the outer wall of the vibrating rod is provided with multiple annular grooves, which correspond one-to-one with the annular protrusions; when the vibrating rod moves up and down reciprocally inside the vibrating cylinder, the annular protrusions and annular grooves cooperate with each other to enhance the vibration effect.

[0017] Furthermore, the bottom of the vibrating rod is provided with a conical head, the diameter of the bottom surface of the conical head being larger than the diameter of the vibrating rod; the outer surface of the conical head is provided with multiple spiral ridges, which are evenly distributed along the axial direction of the conical head; the conical head is detachably connected to the bottom end of the vibrating rod by a threaded connection.

[0018] Furthermore, the transmission mechanism also includes a gearbox, which is fixedly installed on the top of the vibrating cylinder; the upper ends of the drive gear, rack, and transmission shaft are all placed inside the gearbox; the top of the gearbox is provided with an oil inlet, and a sealing bolt is provided at the oil inlet; an observation window is provided on the side wall of the gearbox, and the observation window is made of transparent material.

[0019] Furthermore, the vibration damping assembly also includes a limiting ring, which is fixedly installed on the outer wall of the vibrating cylinder; the inner diameter of the limiting ring is larger than the outer diameter of the connecting plate, and the limiting ring is sleeved on the outer side of the connecting plate; a gap is left between the limiting ring and the connecting plate to limit the horizontal displacement of the vibrating cylinder.

[0020] Furthermore, the adjustment assembly also includes a locking nut, which is sleeved on the adjustment screw; the locking nut is located above the crossbeam and is used to fix the adjustment screw in the adjusted position; the outer circumference of the adjustment handwheel is provided with scale lines, and a baseline is provided at the corresponding position on the crossbeam to indicate the height position of the vibrating cylinder.

[0021] Furthermore, the upper surface of the sealing cover is provided with a feed inlet at its center, and a sealing plug is provided at the feed inlet; the lower surface of the sealing cover is fixedly connected with a stirring blade, which is arranged in a spiral shape; the inner wall of the vibrating cylinder is provided with a guide groove that cooperates with the stirring blade, and the guide groove is arranged along the axial direction of the vibrating cylinder.

[0022] Furthermore, the control panel is equipped with a power switch, a start button, a stop button, a vibration frequency adjustment knob, and a vibration time setting knob; the control panel is equipped with a control circuit, which is electrically connected to the motor and is used to control the motor's start / stop, speed, and running time.

[0023] Furthermore, the bottom of the vibrating cylinder is provided with a discharge port, and an electric valve is provided at the discharge port; the electric valve is electrically connected to the control panel and is used to control the opening and closing of the discharge port; a liquid level sensor is also provided on the outer wall of the vibrating cylinder, and the liquid level sensor is electrically connected to the control panel and is used to detect the liquid level height of the concrete in the vibrating cylinder.

[0024] It also includes a control chip, which is electrically connected to the motor, liquid level sensor, and electric valve. The control chip contains a vibration optimization module, which automatically adjusts vibration parameters based on the viscosity of the concrete and the liquid level. The vibration optimization module performs the following steps:

[0025] S10, Receive concrete liquid level height data sent by the liquid level sensor;

[0026] S20. Determine the current concrete filling degree based on the liquid level height data;

[0027] S30. Obtain the preset concrete viscosity parameters;

[0028] S40. Based on the concrete filling degree and viscosity parameters, select the initial vibration frequency and vibration time from the pre-established vibration parameter database.

[0029] S50. Start the motor and perform vibration operation according to the initial vibration frequency and vibration time;

[0030] S60. After the vibration operation is completed, acquire the liquid level sensor data again and calculate the degree of concrete settlement.

[0031] S70. Adjust the vibration frequency and vibration time according to the degree of settlement to generate optimized vibration parameters;

[0032] S80. Repeat the vibration operation using the optimized vibration parameters until the preset settlement target or the maximum number of vibrations is reached.

[0033] In step S20, the formula for calculating the concrete fill ratio is as follows:

[0034] In the formula, F represents the concrete fill degree, and its value ranges from [value range missing]. [ 0,1 ] h is the current liquid level (m); H is the total height of the vibratory drum (m); α is the filling coefficient, with a default value of 0.2; β is the time decay coefficient, with a default value of 0.1 min. -1 t is the vibration time (min); ε1 is the error term, which follows a normal distribution N(0, 0.01). 2 ).

[0035] Parameter acquisition method: h is obtained directly by liquid level sensor; H is the design parameter of vibratory cylinder; α and β are obtained through the following experimental steps: Step 1: Conduct multiple sets of vibration experiments at different filling heights; Step 2: Record the vibration time and final filling degree of each set of experiments; Step 3: Use nonlinear least squares method to fit and obtain the values ​​of α and β.

[0036] In step S30, the formula for calculating the concrete viscosity parameter is as follows: μ=μ0·(1+k T ·(T-T0))·(1+k w ·(w-w0))+ε2;

[0037] In the formula, μ is the concrete viscosity (Pa·s); μ0 is the reference viscosity, with a default value of 500 Pa·s; k T This is the temperature influence coefficient, with a default value of 0.02℃. -1 T represents the current temperature (°C); T0 represents the reference temperature, taken as 20°C; k w ε is the influence coefficient of moisture content, with a default value of 0.05; w is the current moisture content (%); w0 is the reference moisture content, taken as 10%; ε2 is the error term, following a normal distribution N(0,10). 2 ).

[0038] Parameter acquisition methods: T is obtained through temperature sensor measurement; w is calculated through pre-determined concrete mix proportions; k T and k w The following experimental steps were followed: Step 1: Prepare concrete samples with different temperatures and moisture contents; Step 2: Measure the viscosity of each sample using a rotational viscometer; Step 3: Obtain k using multiple linear regression analysis.T and k w The value of .

[0039] In step S40, the initial vibration frequency and vibration time are calculated using the following formulas: f = f0·(1+a1·F+a2·μ)+ε3; t = t0·(1+b1·F+b2·μ)·+ε4;

[0040] In the formula, f is the initial vibration frequency (Hz); f0 is the reference vibration frequency, with a default value of 50Hz; t is the initial vibration time (s); t0 is the reference vibration time, with a default value of 30s; a1, a2, b1, b2 are undetermined coefficients; F is the concrete filling degree; μ is the concrete viscosity (Pa·s); ε3 and ε4 are error terms, both following a normal distribution n(0,1). 2 ).

[0041] Parameter acquisition method: a1, a2, b1, b2 are obtained through the following steps: Step 1: Conduct multiple sets of vibration experiments with different filling degrees and viscosity; Step 2: Record the optimal vibration frequency and time for each set of experiments; Step 3: Use multiple linear regression analysis to obtain the coefficient values.

[0042] In step S60, the formula for calculating the degree of concrete settlement is as follows:

[0043] In the formula, S represents the degree of settlement, and its value ranges from 1 to 2. [ 0,1 ] h0 is the concrete height before vibration (m); h1 is the concrete height after vibration (m); λ is the settlement time constant, with a default value of 0.05s. -1 t is the vibration time (s); ε5 is the error term, which follows a normal distribution N(0, 0.01). 2 ).

[0044] Parameter acquisition method: h0 and h1 are obtained directly by liquid level sensor; λ is obtained through the following experimental steps: Step 1: Conduct multiple sets of experiments with different vibration times; Step 2: Record the initial height, final height and vibration time of each set of experiments; Step 3: Use nonlinear least squares method to fit the value of λ.

[0045] In step S70, the optimized formula for calculating the vibration parameters is as follows: f new =f·(1+c1·(S) target -S))+ε6;t new =t·(1+c2·(S) target -S))+ε7;

[0046] In the formula, f new The optimized vibration frequency (Hz); tnew The optimized vibration time (s); f and t are the initial vibration frequency and time; c1 and c2 are adjustment coefficients; S target The target settlement level is 0.95 (default value); S represents the actual settlement level; ε6 and ε7 are error terms, both following a normal distribution N(0, 0.5). 2 ).

[0047] Parameter acquisition method: c1 and c2 are obtained through the following steps: Step 1: Conduct multiple sets of vibration experiments with different initial parameters; Step 2: Record the initial parameters, actual settlement degree and final optimal parameters of each set of experiments; Step 3: Use linear regression analysis to obtain the values ​​of c1 and c2.

[0048] Compared with existing technologies, the beneficial effects of the high-viscosity concrete vibration system provided by this invention are as follows: First, the vibration system adopts a unique vibration mechanism design. A vibrating rod is installed inside the vibrating cylinder, and a drive mechanism drives the vibrating rod to reciprocate up and down, achieving effective vibration of the concrete. The inner wall of the vibrating cylinder has annular protrusions that cooperate with the annular grooves on the outer wall of the vibrating rod, effectively enhancing the vibration effect. Simultaneously, the bottom of the vibrating rod has a conical head, and the outer wall has spiral ridges, which further promotes the flow of concrete and the removal of air bubbles.

[0049] Secondly, the system employs an optimized vibration damping mechanism design. The base is connected to the vibratory drum via springs and damping pads, effectively absorbing vibration impacts and protecting the equipment structure from damage. A limit ring is also included to restrict the horizontal displacement of the vibratory drum, further enhancing the system's stability.

[0050] Furthermore, the system is equipped with an intelligent control system. The vibration frequency and time can be adjusted via the control panel to meet the vibration requirements of concretes with varying viscosity. Simultaneously, the system has a built-in vibration optimization module that automatically adjusts vibration parameters based on the concrete's viscosity and liquid level to achieve optimal vibration results. This automatic optimization function is a first among existing vibration equipment.

[0051] In addition, the system also features a mixing function. Spiral mixing blades are installed below the sealed cover, which mix the concrete during vibration, further promoting the removal of air bubbles. Simultaneously, guide grooves are located inside the vibrating cylinder, which, in conjunction with the mixing blades, improve the fluidity of the concrete.

[0052] In summary, this high-viscosity concrete vibration system integrates multiple innovative technologies, effectively addressing the problem that existing vibration equipment cannot meet the vibration requirements of high-viscosity concrete. It not only provides excellent vibration results and is easy to operate, but also automatically adjusts vibration parameters according to actual conditions, significantly improving work efficiency. The application of this system will bring significant economic and social benefits to building construction projects. Attached Figure Description

[0053] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0054] Figure 1 A front view of a high-viscosity concrete vibration system;

[0055] Figure 2 This is a schematic diagram of the internal structure of a high-viscosity concrete vibration system;

[0056] The attached diagram lists the components represented by each number as follows:

[0057] 10. Vibrating cylinder; 11. Protrusion; 20. Vibrating rod; 21. Groove; 22. Conical head; 30. Drive mechanism; 31. Motor; 32. Motor base; 40. Transmission mechanism; 41. Drive gear; 42. Rack; 43. Drive shaft; 45. Gearbox; 50. Fixing frame; 51. Base; 52. Support column; 53. Crossbeam; 60. Shock absorption assembly; 61. Spring; 62. Shock absorption pad; 63. Connecting plate; 64. Limiting ring; 70. Adjusting assembly; 71. Adjusting screw; 72. Adjusting handwheel; 73. Fixing sleeve; 80. Control panel; 90. Sealing cover; 91. Mixing blades; 92. Discharge port. Detailed Implementation

[0058] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

[0059] like Figure 1-2The diagram illustrates an embodiment of a high-viscosity concrete vibration system provided by this invention. This embodiment includes: a vibration cylinder 10, a vibration rod 20, a drive mechanism 30, a transmission mechanism 40, a fixing frame 50, a shock-absorbing component 60, an adjustment component 70, a control panel 80, and a sealing cover 90. The vibration cylinder has a cylindrical structure with an opening at the top and a closed bottom. The vibration rod is cylindrical with a diameter smaller than the inner diameter of the vibration cylinder, and is vertically positioned inside the cylinder. The drive mechanism includes a motor 31, a motor base 32, and a power cord. The motor base is fixedly installed above the vibration cylinder, and the motor is bolted to the base. The power cord is electrically connected to the motor. The transmission mechanism includes a drive gear 41, a rack 42, and a transmission shaft 43. The drive gear is fixedly installed on the output shaft of the motor, and the rack is fixedly installed on the upper end of the transmission shaft. The drive gear meshes with the rack. The lower end of the transmission shaft is fixedly connected to the upper end of the vibration rod. The transmission shaft is connected to the vibration... The vibrating cylinder is slidably connected; the fixed frame includes a base 51, support columns 52, and a crossbeam 53. The base is a square flat plate, the support columns are vertically fixed at the four corners of the base, and the crossbeam is fixedly connected to the top of the four support columns; the shock absorption assembly includes a spring 61, a shock absorption pad 62, and a connecting plate 63. One end of the spring is fixedly connected to the base, and the other end of the spring is fixedly connected to the connecting plate. The shock absorption pad is placed between the connecting plate and the bottom of the vibrating cylinder; the adjustment assembly includes an adjusting screw 71, an adjusting handwheel 72, and a fixing sleeve 73. The adjusting screw is vertically set, and the lower end of the adjusting screw is fixedly connected to the outer wall of the vibrating cylinder. The upper end of the adjusting screw passes through the threaded hole on the crossbeam and is fixedly connected to the adjusting handwheel. The fixing sleeve is fitted on the adjusting screw and is fixedly connected to the crossbeam; the control panel 80 is fixedly installed on one of the support columns and is electrically connected to the motor; the sealing cover is disc-shaped, and the diameter of the sealing cover is larger than the diameter of the opening of the vibrating cylinder. The sealing cover is rotatably connected to the top edge of the vibrating cylinder through a hinge.

[0060] In the above technical solution, the inner wall of the vibrating cylinder is provided with multiple annular protrusions 11, which are evenly distributed along the axial direction of the vibrating cylinder; the outer wall of the vibrating rod is provided with multiple annular grooves 21, which correspond one-to-one with the multiple annular protrusions; when the vibrating rod moves up and down reciprocally inside the vibrating cylinder, the annular protrusions and annular grooves cooperate with each other to enhance the vibration effect.

[0061] Furthermore, in the above technical solution, the bottom of the vibrating rod is provided with a conical head 22, the bottom diameter of the conical head is larger than the diameter of the vibrating rod; the outer surface of the conical head is provided with multiple spiral ridges, which are evenly distributed along the axial direction of the conical head; the conical head is detachably connected to the bottom end of the vibrating rod by a threaded connection.

[0062] Furthermore, in the above technical solution, the transmission mechanism also includes a gearbox 45, which is fixedly installed on the top of the vibrating cylinder; the upper ends of the drive gear, rack, and transmission shaft are all placed inside the gearbox; the top of the gearbox is provided with an oil inlet, and a sealing bolt is provided at the oil inlet; an observation window is provided on the side wall of the gearbox, and the observation window is made of transparent material.

[0063] Furthermore, in the above technical solution, the vibration damping component also includes a limiting ring 64, which is fixedly installed on the outer wall of the vibrating cylinder; the inner diameter of the limiting ring is larger than the outer diameter of the connecting plate, and the limiting ring is sleeved on the outer side of the connecting plate; a gap is left between the limiting ring and the connecting plate to limit the horizontal displacement of the vibrating cylinder.

[0064] Furthermore, in the above technical solution, the adjusting component also includes a locking nut, which is sleeved on the adjusting screw; the locking nut is located above the crossbeam and is used to fix the adjusting screw in the adjusted position; the outer circumference of the adjusting handwheel is provided with scale lines, and the corresponding position on the crossbeam is provided with a baseline line, which is used to indicate the height position of the vibrating cylinder.

[0065] Furthermore, in the above technical solution, a feed inlet is provided at the center of the upper surface of the sealing cover, and a sealing plug is provided at the feed inlet; a stirring blade 91 is fixedly connected to the lower surface of the sealing cover, and the stirring blade is arranged in a spiral shape; a guide groove that cooperates with the stirring blade is provided on the inner wall of the vibrating cylinder, and the guide groove is arranged along the axial direction of the vibrating cylinder.

[0066] Furthermore, in the above technical solution, the control panel is equipped with a power switch, a start button, a stop button, a vibration frequency adjustment knob, and a vibration time setting knob; the control panel is equipped with a control circuit, which is electrically connected to the motor and is used to control the motor's start / stop, speed, and running time.

[0067] Furthermore, in the above technical solution, the bottom of the vibrating cylinder is provided with a discharge port 92, and an electric valve is provided at the discharge port; the electric valve is electrically connected to the control panel and is used to control the opening and closing of the discharge port; a liquid level sensor is also provided on the outer wall of the vibrating cylinder, and the liquid level sensor is electrically connected to the control panel and is used to detect the liquid level height of the concrete in the vibrating cylinder.

[0068] The above technical solution also includes a control chip, which is electrically connected to the motor, liquid level sensor, and electric valve. The control chip contains a vibration optimization module, which automatically adjusts the vibration parameters based on the viscosity of the concrete and the liquid level. The vibration optimization module performs the following steps:

[0069] S10, Receive concrete liquid level height data sent by the liquid level sensor;

[0070] S20. Determine the current concrete filling degree based on the liquid level height data;

[0071] S30. Obtain the preset concrete viscosity parameters;

[0072] S40. Based on the concrete filling degree and viscosity parameters, select the initial vibration frequency and vibration time from the pre-established vibration parameter database.

[0073] S50. Start the motor and perform vibration operation according to the initial vibration frequency and vibration time;

[0074] S60. After the vibration operation is completed, acquire the liquid level sensor data again and calculate the degree of concrete settlement.

[0075] S70. Adjust the vibration frequency and vibration time according to the degree of settlement to generate optimized vibration parameters;

[0076] S80. Repeat the vibration operation using the optimized vibration parameters until the preset settlement target or the maximum number of vibrations is reached.

[0077] The high-viscosity concrete vibration system in this embodiment includes a vibrating cylinder, a vibrating rod, a drive mechanism, a transmission mechanism, a fixing frame, a shock absorption assembly, an adjustment assembly, a control panel, a sealing cover, and a control chip.

[0078] The vibratory compactor is made of 304 stainless steel, with a cylindrical structure, a height of 1500 mm, an inner diameter of 400 mm, and a wall thickness of 10 mm. The top of the compactor is open, while the bottom is closed. Ten annular protrusions, each 5 mm high and 10 mm wide, are evenly distributed along the axial direction on the inner wall of the compactor. A 50 mm diameter discharge port is located at the bottom of the compactor, equipped with a ZKV-25 electric ball valve to control the discharge of concrete. An LUC-M12 ultrasonic level sensor is installed on the outer wall of the compactor to monitor the concrete level inside the compactor in real time.

[0079] The vibratory rod is made of 45# steel, cylindrical in shape, with a diameter of 80 mm and a length of 1400 mm. The outer wall of the vibratory rod has 10 annular grooves corresponding to the protrusions on the inner wall of the vibratory cylinder; each groove is 6 mm deep and 12 mm wide. The bottom of the vibratory rod has a detachable conical head made of high-strength alloy steel, with a bottom diameter of 100 mm and a height of 150 mm. The outer surface of the conical head has six evenly distributed spiral ridges, each 8 mm high and 10 mm wide. The conical head is connected to the bottom of the vibratory rod via an M20*1.5 fine-pitch thread.

[0080] The drive mechanism consists of a Y2-132M-4 three-phase asynchronous motor with a rated power of 7.5 kW and a rated speed of 1450 rpm. The motor is fixed to a 15 mm thick steel motor mount with four M12 bolts. The motor mount is welded to the outer wall of the vibratory drum. The power supply uses a YJV-0.6 / 1kV-36+14 mm² four-core cable, with one end connected to the motor junction box and the other end connected to the control panel.

[0081] The transmission mechanism includes a JZQ350 planetary reducer with a reduction ratio of 1:10. The reducer's input shaft is connected to the motor's output shaft via a coupling, and the output shaft is fixedly connected to the upper end of the vibrating rod. The reducer is secured to the top of the vibrating cylinder with four M16 bolts. An external cast aluminum gearbox is located on the reducer, with an M12 oil filler port on the top and a 50mm diameter tempered glass observation window on the side wall.

[0082] The mounting frame is welded from Q235B steel and includes a square base measuring 2000 x 2000 x 20 mm, four round tubular support columns with a diameter of 100 mm and a height of 2000 mm, and a square crossbeam measuring 2000 x 2000 x 20 mm. The support columns are connected to the base and crossbeam via fillet welds. The surface of the mounting frame is sandblasted and then coated with an epoxy resin anti-corrosion coating with a thickness of not less than 120 micrometers.

[0083] The vibration damping assembly includes four sets of spring dampers, each consisting of two sets of compression springs and one rubber damping pad. The springs are made of 65Mn spring steel, with a free height of 200 mm and a stiffness coefficient of 98 N / mm. The damping pad is made of natural rubber, with a diameter of 150 mm, a thickness of 30 mm, and a Shore hardness of 60. The four sets of dampers are evenly distributed on the base and secured with M16 bolts. The bottom of the vibrating cylinder is connected to the vibration damping assembly via a circular connecting plate with a diameter of 500 mm and a thickness of 20 mm.

[0084] The adjustment assembly consists of four M36*3 adjusting screws, each 500 mm long and made of 45# steel. The lower end of each screw is welded to the outer wall of the vibratory drum, while the upper end passes through a threaded hole on the crossbeam. A 200 mm diameter handwheel is mounted at the top of each screw, with a 0-100 scale engraved on its outer circumference. A reference line is provided at the corresponding position on the crossbeam. Each screw also has an M36 locking nut to secure the adjusted position.

[0085] The control panel is made of 304 stainless steel, measuring 600 x 400 x 200 mm, with an IP65 protection rating. The panel features a power switch, start button, stop button, vibration frequency adjustment knob, vibration time setting knob, and a 7-inch touchscreen. Internally, a Siemens S7-1200 PLC controller is installed to manage the entire system.

[0086] The sealing cap is made of 304 stainless steel, is disc-shaped, with a diameter of 450 mm and a thickness of 10 mm. The sealing cap is connected to the top edge of the vibratory drum via three equally spaced hinges. A 100 mm diameter feed inlet is located at the center of the upper surface of the sealing cap, with a rubber sealing plug at the inlet. Four spiral stirring blades, each 150 mm long, 50 mm wide, and 5 mm thick, are welded to the lower surface of the sealing cap. Correspondingly, four guide grooves, each 60 mm wide and 10 mm deep, are provided on the inner wall of the vibratory drum.

[0087] The control chip uses an STM32F407VGT6 ARM Cortex-M4 processor with a main frequency of 168MHz, 1MB of built-in flash memory and 192KB of RAM. The control chip communicates with the PLC controller via an RS485 interface, acquires liquid level sensor data through an analog input interface, and controls the start and stop of the motor and electric valve through a digital output interface.

[0088] The specific implementation of step S10 is as follows: The control chip sends a read command to the level sensor via the RS485 interface using the ModBus RTU protocol to obtain the current concrete level height data. The level sensor uses the ultrasonic ranging principle, emitting ultrasonic pulses and receiving echoes, calculating the level height by measuring the round-trip time of the ultrasonic waves. The control chip reads the level data every 100 milliseconds, continuously reading 10 times, and takes the average value as the current level height to eliminate measurement errors. The purpose of this step is to accurately obtain the real-time concrete level information, providing basic data for subsequent filling degree calculation and vibration parameter optimization.

[0089] The specific implementation of step S20 is as follows: The control chip calculates the current concrete fill degree based on the liquid level height data obtained in step S10 and the total height of the vibrating cylinder. The fill degree calculation uses an improved exponential decay model, taking into account the influence of vibration time on the fill degree. The specific calculation formula is: Where F is the concrete filling degree, h is the current liquid level (meters), H is the total height of the vibrating cylinder (meters), α is the filling coefficient (default value 0.2), β is the time decay coefficient (default value 0.1 per minute), t is the vibration time (minutes), and ε1 is the error term, following a normal distribution N(0, 0.01). 2The control chip uses 32-bit floating-point numbers for calculations to ensure accuracy. This step transforms the raw liquid level data into more physically meaningful filling parameters, providing a basis for subsequent vibration tamping strategy development.

[0090] The specific implementation of step S30 is as follows: The control chip reads the preset concrete viscosity parameters from the internal EEPROM. The viscosity parameters are obtained using a modified Bingham model, which considers the influence of temperature and moisture content on viscosity. The specific calculation formula is: μ=μ0·(1+k T ·(T-T0))·(1+k w ·(-w0))+ε2. Where μ is the concrete viscosity (Pascal-second), μ0 is the reference viscosity (default value 500 Pascal-second), and k T Here, T is the temperature influence coefficient (default value 0.02 per degree Celsius), T is the current temperature (degrees Celsius), T0 is the reference temperature (20 degrees Celsius), and k is the temperature effect coefficient. w ε is the influence coefficient of moisture content (default value 0.05), w is the current moisture content (percentage), w0 is the reference moisture content (10%), and ε2 is the error term, following a normal distribution N(0,10). 2 Temperature data was acquired using a PT100 temperature sensor installed on the outer wall of the vibratory compactor, and moisture content was calculated based on the pre-determined concrete mix proportions. The purpose of this step was to obtain key parameters reflecting the rheological properties of the concrete, providing an important basis for subsequent optimization of vibration parameters.

[0091] The specific implementation of step S40 is as follows: Based on the filling degree and viscosity parameters obtained in steps S20 and S30, the control chip selects the initial vibration frequency and vibration time from a pre-established vibration parameter database. The database adopts a multi-dimensional lookup table structure and is stored in the flash memory of the control chip. The lookup process uses a linear interpolation algorithm to improve the accuracy of parameter selection. The specific calculation formulas are: f = f0·(1 + a1·F + a2·μ) + ε3, t = t0·(1 + b1·F + b2·μ) + ε4. Where f is the initial vibration frequency (Hz), f0 is the reference vibration frequency (default 50 Hz), t is the initial vibration time (seconds), t0 is the reference vibration time (default 30 seconds), a1, a2, b1, b2 are undetermined coefficients (obtained by least squares fitting from multiple sets of experimental data), F is the concrete filling degree, μ is the concrete viscosity (Pascal-seconds), ε3 and ε4 are error terms, both following a normal distribution N(0,1). 2 The purpose of this step is to select the most suitable initial vibration parameters based on the current state of the concrete, providing a foundation for subsequent vibration operations.

[0092] The specific implementation of step S50 is as follows: Based on the initial vibration frequency and vibration time determined in step S40, the control chip sends a start command and frequency setting value to the frequency converter via the PLC controller. The frequency converter is an ABB general-purpose frequency converter, model ACS580-01-038A-4, with a rated power of 18.5 kW. Based on the received frequency setting value, the frequency converter controls the output voltage and frequency using space vector pulse width modulation (SVPWM) technology, driving the motor to operate at the set speed. Simultaneously, the control chip starts a software timer to control the vibration time. During vibration, the control chip monitors the motor's operating current in real time via a current transformer. If the detected current exceeds 1.5 times the rated value, the vibration operation is immediately stopped and an alarm is triggered. The purpose of this step is to execute the actual vibration operation while ensuring the safe operation of the equipment.

[0093] The specific implementation of step S60 is as follows: After the vibration operation is completed, the control chip calls the method in step S10 again to obtain the liquid level sensor data and calculate the settlement degree of the concrete. The settlement degree is calculated using an exponential decay model, taking into account the influence of vibration time on settlement. The specific calculation formula is: Where S represents the degree of settlement, h0 is the concrete height before vibration (meters), h1 is the concrete height after vibration (meters), λ is the settlement time constant (default value 0.05 seconds), t is the vibration time (seconds), and ε5 is the error term, following a normal distribution N(0, 0.01). 2 The control chip continuously calculates the settlement degree five times, and takes the average value as the final result to reduce the impact of measurement errors. This step aims to evaluate the effectiveness of the current vibration operation and provide a basis for subsequent parameter optimization.

[0094] The specific implementation of step S70 is as follows: Based on the settlement degree calculated in step S60 and combined with the preset target settlement degree, the control chip uses a gradient descent algorithm to adjust the vibration frequency and vibration time, generating optimized vibration parameters. The specific calculation formula is: f new =f·(1+c1·(S) target -S))+ε6,t new =t·(1+c2·(S) target -S))+ε7. Where, f new For the optimized vibration frequency (Hertz), t new The optimized vibration time (in seconds) is given by f and t, where f and t are the initial vibration frequency and time, and c1 and c2 are adjustment coefficients (obtained by least squares fitting of multiple sets of experimental data). S target ε0 represents the target settlement degree (default value is 0.95), S represents the actual settlement degree, and ε6 and ε7 are error terms, both following a normal distribution N(0, 0.5). 2The control chip uses 32-bit floating-point numbers for calculations to ensure accuracy. During optimization, the control chip checks whether the calculation results are within the preset safety range (vibration frequency: 20-80 Hz, vibration time: 10-120 seconds). If they exceed the range, boundary values ​​are used. The purpose of this step is to dynamically adjust the vibration parameters based on the actual vibration effect to achieve the best vibration result.

[0095] The specific implementation of step S80 is as follows: The control chip uses the vibration parameters optimized in step S70 to repeatedly execute the operations of steps S50 to S70. After each cycle, the control chip determines whether the preset settlement target or the maximum number of vibrations has been reached. The criterion for determining the settlement target is: the difference between the current settlement degree and the target settlement degree is less than 0.02. The maximum number of vibrations is set to 5 by default. If the settlement target or the maximum number of vibrations is reached, the control chip stops the vibration operation and sends a completion signal to the PLC controller. If the target and the maximum number of vibrations are not reached, the next cycle continues. During the cycle, the control chip monitors the temperature change inside the vibrating cylinder in real time. If the temperature rises by more than 5 degrees Celsius, the vibration operation is forcibly terminated and an alarm is triggered to prevent over-vibration from causing a decline in concrete performance. The purpose of this step is to ensure that the concrete reaches the optimal compaction state through multiple optimizations and vibrations, while avoiding the adverse effects of over-vibration on concrete quality.

[0096] Throughout the vibration process, the control chip also performs the following auxiliary functions:

[0097] 1. Real-time Data Recording: The control chip records the parameters (frequency, time), settlement degree, temperature, and other data for each vibration cycle into an internal circular buffer. The buffer size is 1MB, which can store detailed data from the most recent 1000 vibration cycles. This data can be exported via the RS485 interface for subsequent quality analysis and process optimization.

[0098] 2. Adaptive Parameter Adjustment: The control chip dynamically adjusts the baseline vibration frequency and time based on historical vibration data using an Exponentially Weighted Moving Average (EWMA) algorithm. The adjustment formula is: X new =α·X current +(1-α)·X old Where X represents the reference frequency or time, and α is the smoothing coefficient (default value 0.2). This adaptive adjustment allows the system to gradually adapt to the characteristics of different batches of concrete.

[0099] 3. Fault Diagnosis: The control chip monitors parameters such as motor current, vibratory rod position, and liquid level changes to achieve real-time fault diagnosis. For example, a sudden drop in motor current may indicate a problem with the transmission system; an abnormal rise in liquid level during vibration may indicate concrete segregation. Once an abnormality is detected, the control chip will immediately stop vibration and issue an alarm.

[0100] 4. Energy Consumption Optimization: The control chip uses a dynamic programming algorithm to calculate the optimal vibration strategy based on the relationship between vibration effect and energy consumption. The energy consumption calculation formula is: Where E is the total energy consumption (joules), P is the instantaneous power (watts), f is the vibration frequency (hertz), and t is the vibration time (seconds). By optimizing energy consumption, production costs can be reduced while ensuring vibration quality.

[0101] 5. Human-Machine Interaction: The control chip provides a user-friendly interface via a 7-inch touchscreen. Operators can view real-time vibration parameters, historical data curves, equipment status, and other information through the touchscreen. The interface adopts a multi-level menu structure, mainly including four modules: real-time monitoring, parameter setting, data query, and system maintenance. In the parameter setting module, authorized personnel can adjust key parameters such as the target settlement degree and the maximum number of vibrations.

[0102] 6. Remote Monitoring: The control chip has a built-in 4G communication module, supporting remote data upload and control. The system uploads key operating parameters to the cloud server every 10 minutes, allowing administrators to view the equipment's operating status in real time via a mobile app. In emergencies, administrators can send remote shutdown commands via the app.

[0103] 7. Vibration Analysis: The control chip collects data from the accelerometers mounted on the vibrating bar and performs real-time vibration spectrum analysis. A Fast Fourier Transform (FFT) algorithm is used to convert the time-domain signal into a frequency-domain signal. By monitoring the vibration intensity in specific frequency bands, the vibration effect can be evaluated, and equipment anomalies can be detected promptly.

[0104] 8. Temperature Compensation: Considering the impact of ambient temperature on concrete performance, the control chip automatically adjusts the vibration parameters based on the current temperature. The temperature compensation formula is: f c =f·(1+k) t ·(TT r )). Among them, f c f is the compensated frequency (Hertz), f is the original frequency (Hertz), and k is the frequency. t Here, T is the temperature compensation factor (default value 0.005 per degree Celsius), and T is the current temperature (degrees Celsius). r Reference temperature (20 degrees Celsius).

[0105] 9. Automatic Cleaning: To prevent scale buildup on the surface of the vibratory drum and vibratory rod, the system automatically performs a cleaning program after each day's work. The cleaning process includes: injecting clean water into the vibratory drum, starting the vibratory rod at low speed for 30 seconds, draining the wastewater, and repeating this process 3 times. The amount of water used for cleaning and the number of cleaning cycles can be set on the touchscreen.

[0106] 10. Safety Protection: The system is equipped with multiple safety protection mechanisms, including: overcurrent protection (power off immediately when the motor current exceeds 1.5 times the rated value), overheat protection (shut down when the motor temperature exceeds 85 degrees Celsius), vibration over-limit protection (shut down when the vibration acceleration exceeds 10g), and emergency stop (emergency stop buttons are provided on both the touch screen and the outside of the control box).

[0107] 11. Data Encryption: Considering that vibration parameters may involve core enterprise technologies, the control chip encrypts the stored parameters and historical data. The AES-256 encryption algorithm is used, with the key generated by a hardware unique identifier (UID) and a random number. This prevents unauthorized reading and tampering of the data.

[0108] 12. Automatic Identification: The system supports automatic identification of different models of vibratory compactors. An RFID tag is installed at the bottom of the vibratory compactor, and the control box has a built-in RFID reader. When replacing a vibratory compactor, the system automatically reads the tag information and loads the corresponding parameter configuration, requiring no manual intervention.

[0109] 13. Predictive Maintenance: The control chip analyzes historical operating data and uses machine learning algorithms (such as Support Vector Machine, SVM) to predict potential equipment failures. The system will issue maintenance reminders before the expected failure occurs.

[0110] 14. Batch Tracking: For each vibration operation, the control chip generates a unique batch number and associates vibration parameters, operation time, operator information, etc., with that batch number. This enables full-process tracking of concrete quality, facilitating subsequent quality control and problem tracing.

[0111] 15. Automatic Leveling: The system monitors the pressure sensor data at the four corners of the vibratory drum to determine if the drum is level. If tilting is detected, the control chip automatically controls the four electric push rods of the adjustment component to make fine adjustments, ensuring that the vibratory drum always remains level, thereby guaranteeing the uniformity of the vibration effect.

[0112] In summary, the high-viscosity concrete vibration system of this embodiment achieves automated, intelligent, and refined control of the concrete vibration process by precisely controlling vibration parameters and combining various intelligent algorithms and functions. The system can adapt to concretes with different properties and can adaptively adjust based on actual vibration results, while also considering factors such as production efficiency, product quality, and energy consumption. Furthermore, the system's remote monitoring, data analysis, and predictive maintenance functions provide strong technical support for concrete production management, contributing to improved overall production efficiency and product quality stability.

[0113] Example

[0114] A large-scale construction project is currently carrying out foundation pouring work for a high-rise building. To ensure the quality and density of the concrete, the project team decided to adopt the high-viscosity concrete vibration system of this invention. The following are specific examples of the system's practical application.

[0115] First, based on the architectural design requirements and geological conditions, the engineering technicians determined the required concrete mix proportions. This concrete has a compressive strength grade of C50, a slump of 180 mm, and a viscosity range of 500-800 Pascal-seconds. Considering the depth and complexity of the foundation, high-performance vibratory compaction equipment was required.

[0116] The project team selected the high-viscosity concrete vibration system of this invention, whose main parameters are as follows: the height of the vibrating cylinder is 1500 mm and the inner diameter is 400 mm; the diameter of the vibrating rod is 80 mm and the length is 1400 mm; the power of the drive motor is 7.5 kW; and the control system uses an STM32F407VGT6 chip.

[0117] During the actual construction process, the technicians first installed the vibration system in the designated location. After installation, the system was initialized. The following parameters were entered through the touch screen interface: target settlement degree of 0.95, maximum number of vibrations of 5, vibration frequency range of 20-80 Hz, and vibration time range of 10-120 seconds.

[0118] Subsequently, a concrete mixer truck transports the freshly mixed concrete to the construction site. Operators open the feed inlet at the top of the vibrating drum and pour the concrete into it. The feed inlet automatically closes when the level sensor detects that the concrete height has reached 1200 mm.

[0119] The system begins executing the vibration program. The following is a detailed description of the first vibration step:

[0120] 1. Liquid level detection: The liquid level sensor reads data 10 times, with an average value of 1198 mm.

[0121] 2. Fill factor calculation: The fill factor is calculated to be 0.799 according to the formula.

[0122] 3. Viscosity parameter acquisition: The temperature sensor measured the current temperature to be 28 degrees Celsius. According to the preset concrete mix proportion, the water content is 9.8%. The calculated current viscosity is 685 Pascal-seconds.

[0123] 4. Initial vibration parameter selection: The system queries the database and selects an initial vibration frequency of 55 Hz and a vibration time of 40 seconds.

[0124] 5. Vibration execution: The frequency converter controls the motor to operate at a frequency of 55 Hz for 40 seconds. During this process, the motor current remains stable at around 15 amps without any abnormal fluctuations.

[0125] 6. Settlement Calculation: After vibration, the liquid level sensor read the data again, with an average value of 1165 mm. The calculated settlement degree was 0.825.

[0126] 7. Parameter optimization: Based on the difference between the settlement degree and the target value, the system calculates new vibration parameters: the frequency is adjusted to 62 Hz and the time is extended to 50 seconds.

[0127] The system then began a second vibration. After the second vibration, the settlement level reached 0.91. The system parameters were then optimized again, and a third vibration was performed. After the third vibration, the settlement level reached 0.938, very close to the target value of 0.95.

[0128] Considering that the value was already very close to the target, the system decided to perform one more fine-tuning vibration. The fourth vibration used a frequency of 65 Hz and lasted for 30 seconds. After the vibration, the final settlement reached 0.949, meeting the set target requirements.

[0129] Table 1 shows the key data for the entire vibration process:

[0130] Number of vibrations Frequency (Hertz) Time (seconds) Starting height (mm) End height (mm) Settlement degree 1 55 40 1198 1165 0.825 2 62 50 1165 1140 0.910 3 64 45 1140 1125 0.938 4 65 30 1125 1120 0.949

[0131] Throughout the vibration process, the system also performed the following auxiliary functions:

[0132] 1. Real-time data recording: The parameters, effects, and environmental data of each vibration cycle are recorded in the system's internal storage. This data can be viewed via a touchscreen or exported to external devices via an RS485 interface.

[0133] 2. Energy consumption optimization: The system calculated the total energy consumption of this vibration operation to be 0.38 kWh. Compared with traditional manual control, this saves approximately 20% of energy consumption.

[0134] 3. Remote monitoring: The project manager at the construction site monitored the entire vibration process in real time via a mobile app. He observed that the vibration effect was good and no abnormalities occurred.

[0135] 4. Vibration Analysis: Data collected by the accelerometer shows that at a frequency of 65 Hz, the peak vibration acceleration of the vibrating rod reaches 8.2g, which is within the ideal working range.

[0136] 5. Temperature compensation: Since the current temperature (28 degrees Celsius) is higher than the reference temperature (20 degrees Celsius), the system slightly increases the frequency to 65.2 Hz during the last vibration to compensate for the effect of temperature on the fluidity of concrete.

[0137] 6. Automatic Leveling: During the vibration process, the system detects that the vibratory drum is slightly tilted (approximately 0.5 degrees). The adjustment component automatically adjusts the height of the four support points to restore the vibratory drum to a horizontal state.

[0138] After vibration is complete, the operator opens the discharge port and pours the vibrated concrete into the pouring location. During the discharge process, the system continues to monitor the flow of the concrete to ensure that no segregation occurs.

[0139] After the day's work was completed, the system automatically executed a cleaning procedure. First, 100 liters of clean water were injected into the vibratory drum, and the vibratory rod was started to run at a low speed of 30 Hz for 30 seconds, after which the wastewater was discharged. This process was repeated three times to ensure the equipment was clean.

[0140] The next morning, technicians reviewed the daily report generated by the system. The report showed that 32 batches of concrete vibration were completed the previous day, with an average of 3.6 vibrations per batch and an average energy consumption of 0.41 kWh per batch. The system also compared data from the past week and found that yesterday's vibration efficiency was 5% higher, which may be related to the adaptive parameter adjustments made the day before.

[0141] The technicians also noticed a warning message from the system: based on the trend of motor current changes, the drive shaft was expected to need replacement after approximately 200 operating hours. The technicians then scheduled maintenance for the following week.

[0142] Over the next month, the high-viscosity concrete vibration system operated stably, completing approximately 1,000 batches of concrete vibration work. During this period, the system's adaptive function continuously optimized the vibration parameters, reducing the average number of vibrations per batch from the initial 3.6 to 3.2, thus improving efficiency and reducing the risk of over-vibration.

[0143] The project team conducted random sampling tests on the concrete produced within one month, and the results showed:

[0144] 1. Compressive strength: The average compressive strength of the 50 samples after 28 days was 58.3 MPa, with a standard deviation of 1.2 MPa, all meeting the design requirement of C50 grade.

[0145] 2. Compaction: Using ultrasonic testing, the average sound velocity at 100 measuring points was 4580 m / s, with a minimum of 4510 m / s, indicating that the concrete has very good compactness.

[0146] 3. Uniformity: The rebound value of 200 measuring points was 4.2% by rebound test, which is far below the allowable 10% in the specification, indicating that the uniformity of the concrete is excellent.

[0147] These test results fully demonstrate the excellent performance of the high-viscosity concrete vibration system of the present invention in ensuring concrete quality.

[0148] Specifically, the principle of this invention is as follows: The high-viscosity concrete vibration system proposed in this invention mainly consists of a vibrating cylinder, a vibrating rod, a drive mechanism, a transmission mechanism, a fixing frame, a vibration damping assembly, an adjustment assembly, a control panel, and a sealing cover. Its working principle is as follows:

[0149] First, the motor in the drive mechanism drives the vibratory rod to reciprocate up and down via a transmission mechanism. Specifically, a drive gear is mounted on the motor's output shaft, and a rack meshing with it is mounted on the transmission shaft, the lower end of which is connected to the vibratory rod. The motor's operation drives the drive gear to rotate, transmitting the rotational force through the gear meshing to the rack and transmission shaft, ultimately causing the vibratory rod to move up and down. The vibratory rod then reciprocates within the vibratory drum, thus compacting the concrete filled within it.

[0150] To enhance the vibration effect, the inner wall of the vibratory cylinder has multiple annular protrusions, and the outer wall of the vibratory rod has corresponding annular grooves. During vibration, the annular protrusions and grooves work together to create intermittent obstruction, effectively disrupting the continuity of the concrete and promoting the full release of air bubbles. Simultaneously, the bottom of the vibratory rod has a conical head, and the outer wall has spiral ridges, which further improve the fluidity of the concrete and increase vibration efficiency.

[0151] To protect the vibration system, an optimized damping mechanism design is employed. The vibratory drum is connected to the base of the mounting frame via springs and damping pads, effectively absorbing vibration impacts and reducing damage to the equipment structure. A limit ring is also included to restrict the horizontal displacement of the vibratory drum, further enhancing system stability.

[0152] In addition, the system features automatic vibration parameter optimization. Vibration frequency and time can be manually set via various adjustment devices on the control panel to meet the vibration requirements of different viscous concrete types. The system's built-in vibration optimization module automatically selects the optimal vibration parameters based on real-time monitoring of the concrete level and preset viscosity parameters, and continuously optimizes them to ensure ideal vibration results.

[0153] The sealed cap is equipped with a feed inlet and mixing blades, which can mix the concrete during vibration. At the same time, the inner wall of the vibratory cylinder has guide grooves, which, in conjunction with the mixing blades, can improve the fluidity of the concrete and promote the full removal of air bubbles.

[0154] In summary, this high-viscosity concrete vibration system, through its unique vibration mechanism design, optimized damping mechanism, intelligent control system, and integrated mixing function, achieves highly efficient vibration of high-viscosity concrete, solving the problem that existing technologies cannot meet the vibration requirements of this type of concrete. It not only provides excellent vibration results and is easy to operate, but also has the function of automatically optimizing vibration parameters, significantly improving work efficiency. This innovative vibration system is bound to bring broad application prospects to building construction projects.

[0155] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A high-viscosity concrete vibration system, characterized in that, The system includes: a vibrating cylinder, a vibrating rod, a drive mechanism, a transmission mechanism, a mounting frame, a shock-absorbing assembly, an adjustment assembly, a control panel, and a sealing cover. The vibrating cylinder has a cylindrical structure with an opening at the top and a closed bottom. The vibrating rod is cylindrical with a diameter smaller than the inner diameter of the vibrating cylinder, and is vertically positioned inside the cylinder. The drive mechanism includes a motor, a motor mount, and a power cord. The motor mount is fixedly installed above the vibrating cylinder, and the motor is bolted to the mount. The power cord is electrically connected to the motor. The transmission mechanism includes a drive gear. The system comprises a wheel, rack, and drive shaft. The drive gear is fixedly mounted on the output shaft of the motor, and the rack is fixedly mounted on the upper end of the drive shaft. The drive gear meshes with the rack. The lower end of the drive shaft is fixedly connected to the upper end of the vibrating rod, and the drive shaft is slidably connected to the vibrating cylinder. The mounting frame includes a base, support columns, and a crossbeam. The base is a square flat plate, the support columns are vertically fixed at the four corners of the base, and the crossbeam is fixedly connected to the top of the four support columns. The vibration damping assembly includes a spring, a damping pad, and a connecting plate. One end of the spring is fixedly connected to the base, and the other end of the spring is fixedly connected to the connecting plate. The damping pad is... Between the connecting plate and the bottom of the vibrating cylinder; the adjusting assembly includes an adjusting screw, an adjusting handwheel, and a fixing sleeve. The adjusting screw is vertically arranged, with its lower end fixedly connected to the outer wall of the vibrating cylinder, and its upper end passing through a threaded hole on the crossbeam and fixedly connected to the adjusting handwheel. The fixing sleeve is fitted onto the adjusting screw and fixedly connected to the crossbeam. The control panel is fixedly installed on one of the support columns and is electrically connected to the motor. The sealing cover is disc-shaped, with a diameter larger than the diameter of the opening of the vibrating cylinder. The sealing cover is rotatably connected to the top edge of the vibrating cylinder via a hinge. The vibrating cylinder is equipped with a discharge port at its bottom, and an electric valve at the discharge port. The electric valve is electrically connected to the control panel and is used to control the opening and closing of the discharge port. A liquid level sensor is also provided on the outer wall of the vibrating cylinder and is electrically connected to the control panel to detect the liquid level of the concrete inside the vibrating cylinder. The system also includes a control chip, which is electrically connected to the motor, the liquid level sensor, and the electric valve. The control chip contains a vibration optimization module, which is used to automatically adjust the vibration parameters according to the viscosity of the concrete and the liquid level.

2. The high-viscosity concrete vibration system according to claim 1, characterized in that, The inner wall of the vibrating cylinder is provided with multiple annular protrusions, which are evenly distributed along the axial direction of the vibrating cylinder; the outer wall of the vibrating rod is provided with multiple annular grooves, which correspond one-to-one with the annular protrusions; when the vibrating rod moves up and down reciprocally inside the vibrating cylinder, the annular protrusions and annular grooves cooperate with each other to enhance the vibration effect.

3. The high-viscosity concrete vibration system according to claim 2, characterized in that, The bottom of the vibrating rod is provided with a conical head, the diameter of the bottom surface of the conical head is larger than the diameter of the vibrating rod; the outer surface of the conical head is provided with multiple spiral ridges, which are evenly distributed along the axial direction of the conical head; the conical head is detachably connected to the bottom end of the vibrating rod by a threaded connection.

4. The high-viscosity concrete vibration system according to claim 3, characterized in that, The transmission mechanism also includes a gearbox, which is fixedly installed on the top of the vibrating cylinder; the upper ends of the drive gear, rack, and transmission shaft are all placed inside the gearbox; the top of the gearbox is provided with an oil inlet, and a sealing bolt is provided at the oil inlet; an observation window is provided on the side wall of the gearbox, and the observation window is made of transparent material.

5. A high-viscosity concrete vibration system according to claim 4, characterized in that, The vibration damping assembly also includes a limiting ring, which is fixedly installed on the outer wall of the vibrating cylinder; the inner diameter of the limiting ring is larger than the outer diameter of the connecting plate, and the limiting ring is sleeved on the outer side of the connecting plate; a gap is left between the limiting ring and the connecting plate to limit the horizontal displacement of the vibrating cylinder.

6. The high-viscosity concrete vibration system according to claim 5, characterized in that, The adjustment assembly also includes a locking nut, which is sleeved on the adjusting screw. The locking nut is located above the crossbeam and is used to fix the adjusting screw in the adjusted position. The outer circumference of the adjusting handwheel is provided with scale lines, and a baseline is provided at the corresponding position on the crossbeam to indicate the height position of the vibrating cylinder.

7. A high-viscosity concrete vibration system according to claim 6, characterized in that, The upper surface of the sealing cover has a feed inlet at its center and a sealing plug at the feed inlet; the lower surface of the sealing cover is fixedly connected to a stirring blade, which is arranged in a spiral shape; the inner wall of the vibrating cylinder is provided with a guide groove that cooperates with the stirring blade, and the guide groove is arranged along the axial direction of the vibrating cylinder.

8. A high-viscosity concrete vibration system according to claim 7, characterized in that, The control panel is equipped with a power switch, a start button, a stop button, a vibration frequency adjustment knob, and a vibration time setting knob; the control panel contains a control circuit, which is electrically connected to the motor and is used to control the motor's start / stop, speed, and running time.

9. A high-viscosity concrete vibration system according to claim 1, characterized in that, The vibration optimization module performs the following steps: S10, Receive concrete liquid level height data sent by the liquid level sensor; S20. Determine the current concrete filling degree based on the liquid level height data; S30. Obtain the preset concrete viscosity parameters; S40. Based on the concrete filling degree and viscosity parameters, select the initial vibration frequency and vibration time from the pre-established vibration parameter database. S50. Start the motor and perform vibration operation according to the initial vibration frequency and vibration time; S60. After the vibration operation is completed, acquire the liquid level sensor data again and calculate the degree of concrete settlement. S70. Adjust the vibration frequency and vibration time according to the degree of settlement to generate optimized vibration parameters; S80. Repeat the vibration operation using the optimized vibration parameters until the preset settlement target or the maximum number of vibrations is reached.

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